JP5065544B2 - Manufacturing method of wire harness - Google Patents

Manufacturing method of wire harness Download PDF

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JP5065544B2
JP5065544B2 JP2012512845A JP2012512845A JP5065544B2 JP 5065544 B2 JP5065544 B2 JP 5065544B2 JP 2012512845 A JP2012512845 A JP 2012512845A JP 2012512845 A JP2012512845 A JP 2012512845A JP 5065544 B2 JP5065544 B2 JP 5065544B2
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shape
mold
predetermined
maintaining member
wire harness
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JPWO2011136201A1 (en
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敦 村田
信行 平野
理 佐藤
真 神谷
聡 谷川
伸一 五十嵐
伸昌 瀧原
幸裕 白藤
正道 山際
裕 高田
啓人 上野
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Sumitomo Wiring Systems Ltd
AutoNetworks Technologies Ltd
Sumitomo Electric Industries Ltd
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Sumitomo Wiring Systems Ltd
AutoNetworks Technologies Ltd
Sumitomo Electric Industries Ltd
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/012Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/012Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
    • H01B13/01254Flat-harness manufacturing
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06Insulating conductors or cables

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Details Of Indoor Wiring (AREA)

Description

本発明は、ワイヤーハーネスの製造方法に関するものであり、詳しくは、ワイヤーハーネスを構成する電線の所定の部分を所定の形状に維持する形状維持部材(この形状維持部材は、ワイヤーハーネスを構成する電線を保護するプロテクタとしての機能も有する)が設けられたワイヤーハーネスの製造方法に関するものである。   The present invention relates to a method of manufacturing a wire harness, and more specifically, a shape maintaining member that maintains a predetermined shape of a wire constituting the wire harness in a predetermined shape (the shape maintaining member is an electric wire that forms the wire harness). This also relates to a method of manufacturing a wire harness provided with a function as a protector for protecting the wire).

自動車などの車両の内部には、電気装置や電子機器などを相互に接続するためのワイヤーハーネスが配索される。このワイヤーハーネスは、車両などの内部を所定の経路に沿って配索されるため、ワイヤーハーネスを製造する段階において、ワイヤーハーネスが配索しやすい形状に形成されることがある。たとえば、ワイヤーハーネス(すなわち、ワイヤーハーネスを構成する電線)が、配索される経路の形状に応じた形状に形成されることがある。   Inside a vehicle such as an automobile, a wire harness for connecting electrical devices and electronic devices to each other is routed. Since this wire harness is routed inside a vehicle or the like along a predetermined route, the wire harness may be formed in a shape that is easy to route in the stage of manufacturing the wire harness. For example, a wire harness (that is, an electric wire constituting the wire harness) may be formed in a shape corresponding to the shape of a route to be routed.

このため、ワイヤーハーネスを構成する電線の所定の箇所(たとえば、電線が分岐している箇所や、電線が屈曲もしくは湾曲している箇所)には、形状維持部材が装着されることがある。また、ワイヤーハーネスを構成する電線を保護するために、所定の箇所にプロテクタが装着されることがある。このような形状維持部材やプロテクタは、一般的には内部が空洞のシェル状の部材(たとえば筒状の部材であって、その軸線が所定の形状に形成される部材)が適用される。そして、このような形状維持部材やプロテクタは、一般的には樹脂材料からなり射出成形により製造される射出成形品が適用される。   For this reason, a shape maintenance member may be attached to a predetermined part (for example, a part where the electric wire is branched or a part where the electric wire is bent or curved) of the electric wire constituting the wire harness. Moreover, in order to protect the electric wire which comprises a wire harness, a protector may be mounted | worn at a predetermined location. Such a shape maintaining member or protector is generally a shell-like member having a hollow inside (for example, a cylindrical member whose axis is formed in a predetermined shape). In general, an injection molded product made of a resin material and manufactured by injection molding is applied to the shape maintaining member and the protector.

このような射出成形品の形状維持部材が適用される構成によれば、ワイヤーハーネスを構成する電線の所定の箇所に形状維持部材を装着することにより、当該装着された箇所を所定の形状に形成することができる。また、射出成形品のプロテクタが適用される構成によれば、装着された箇所がプロテクタにより保護される。しかしながら、射出成形品の形状維持部材やプロテクタが適用される構成は、次のような問題を有する。   According to the configuration to which the shape maintaining member of such an injection molded product is applied, the mounted portion is formed into a predetermined shape by mounting the shape maintaining member on the predetermined portion of the electric wire constituting the wire harness. can do. Moreover, according to the structure to which the protector of the injection molded product is applied, the mounted portion is protected by the protector. However, the configuration to which the shape maintaining member and the protector of the injection molded product are applied has the following problems.

まず、このような形状維持部材やプロテクタを製造するためには、射出成形型が必要となる。射出成形型は一般的に高価であることから、形状維持部材やプロテクタの製造コストや価格が上昇する。また、ワイヤーハーネスを構成する電線に形状維持部材やプロテクタを装着する作業が必要となるから、作業工数が増加し、このため製造コストの上昇を招くおそれがある。   First, in order to manufacture such a shape maintenance member and protector, an injection mold is required. Since the injection mold is generally expensive, the manufacturing cost and price of the shape maintaining member and the protector increase. Moreover, since the operation | work which mounts a shape maintenance member and a protector on the electric wire which comprises a wire harness is required, an operation man-hour increases and there exists a possibility of causing the raise of manufacturing cost for this.

また、シェル状の形状維持部材やプロテクタがワイヤーハーネスを構成する電線に装着される構成においては、電線と形状維持部材やプロテクタの内周面との間に隙間が存在することがある。このため、ワイヤーハーネスに振動や衝撃が加わると、電線が形状維持部材やプロテクタの内周面に衝突し、打音や衝撃音が発生する。このような打音や衝撃音の発生は、ワイヤーハーネスが適用された車両などの品位を低下させるおそれがある。また、電線が形状維持部材やプロテクタの内周面に衝突することによって、損傷するおそれもある。   Moreover, in the structure with which a shell-shaped shape maintenance member and a protector are mounted | worn with the electric wire which comprises a wire harness, a clearance gap may exist between an electric wire and the inner peripheral surface of a shape maintenance member or a protector. For this reason, when vibration or impact is applied to the wire harness, the electric wire collides with the inner peripheral surface of the shape maintaining member or the protector, and hitting sound or impact sound is generated. The occurrence of such a hitting sound or impact sound may reduce the quality of a vehicle or the like to which the wire harness is applied. Moreover, there exists a possibility that it may be damaged when an electric wire collides with the internal peripheral surface of a shape maintenance member or a protector.

電線が形状維持部材やプロテクタの内周面に衝突することを防止する構成としては、たとえば、形状維持部材やプロテクタの内部に緩衝材(たとえばスポンジ状の部材)を配設する構成がある。しかしながらこのような構成では、形状維持部材やプロテクタの内部に緩衝材を配設する作業が必要となるから、作業工数が増加し、製造コストの上昇を招くおそれがある。また、部品点数が増加するため、部品コストの上昇を招くおそれもある。   As a configuration for preventing the electric wire from colliding with the inner peripheral surface of the shape maintaining member or the protector, for example, there is a configuration in which a buffer material (for example, a sponge-like member) is disposed inside the shape maintaining member or the protector. However, in such a configuration, an operation for disposing the cushioning material inside the shape maintaining member or the protector is required, which increases the number of work steps and may increase the manufacturing cost. Moreover, since the number of parts increases, there is a possibility that the cost of parts may increase.

射出成形品ではないプロテクタを用いる構成としては、たとえば、フラット回路体の周囲に熱可塑性材料からなるプロテクタを形成する構成が提案されている(特許文献1参照)。すなわち特許文献1に開示される構成は、熱可塑性樹脂材料からなる二枚の被覆材でフラット回路体を挟み、これらを加熱しながら金型によりプレス成形することにより、二枚の被覆材をフラット回路体に密着させるとともに、二枚の被覆材どうしが接触する部分を溶着させる。このような構成によれば、二枚の被覆材がプロテクタとなるから、射出成形品のプロテクタが不要となる。このため、部品コストの削減を図ることができる。   As a configuration using a protector that is not an injection molded product, for example, a configuration is proposed in which a protector made of a thermoplastic material is formed around a flat circuit body (see Patent Document 1). That is, in the configuration disclosed in Patent Document 1, a flat circuit body is sandwiched between two coating materials made of a thermoplastic resin material, and the two coating materials are flattened by pressing them with a mold while heating them. While making it contact | adhere to a circuit body, the part which two coating | covering materials contact is welded. According to such a configuration, since the two covering materials serve as protectors, the protector for the injection molded product is not necessary. For this reason, reduction of parts cost can be aimed at.

ところで、ワイヤーハーネスは、一般的に、車両などの内部の所定の経路に沿って配索される。このため、被覆材の断面形状および寸法や、被覆材の軸線形状は、配索される経路の形状および寸法に応じて設定されることが好ましい。たとえば、配索される経路の形状および寸法に略等しい形状や、配索作業において便利となるような形状に設定されることが好ましい。   By the way, the wire harness is generally routed along a predetermined route inside a vehicle or the like. For this reason, it is preferable that the cross-sectional shape and dimensions of the covering material and the axial shape of the covering material are set according to the shape and dimensions of the route routed. For example, it is preferable to set a shape that is substantially equal to the shape and size of the route to be routed, or a shape that is convenient in the routing operation.

しかしながら、特許文献1に開示される構成は、次のような問題点を有すると考えられる。プレス成形直後の被覆材は高温であるから、被覆材が塑性変形しやすい状態にある。このため、プレス成形されたワイヤーハーネスを金型から取り出して搬送すると、フラット回路体や被覆材の自重によって撓み変形するおそれがある。また、金型からの取り出しや搬送の際に被覆材に触れると、触れた箇所やその近傍が変形するおそれがある。このように、プレス成形後において、ワイヤーハーネスに望まない変形が生じるおそれがある。したがって、被覆材の軸線形状を、配索される経路の形状および寸法に応じて成形しても、成形後において変形が生じないようにすることが困難であるから、成形した形状を維持することが困難である。   However, the configuration disclosed in Patent Document 1 is considered to have the following problems. Since the coating material immediately after the press molding is at a high temperature, the coating material is easily plastically deformed. For this reason, when the press-molded wire harness is taken out from the mold and conveyed, there is a possibility that the flat circuit body or the covering material may be bent and deformed. Further, if the coating material is touched during taking out from the mold or transporting, the touched portion or its vicinity may be deformed. Thus, there is a possibility that undesired deformation occurs in the wire harness after press molding. Therefore, it is difficult to prevent deformation after molding even if the axial shape of the covering material is molded according to the shape and dimensions of the route to be routed. Is difficult.

また、特許文献1には、金型を冷却してからワイヤーハーネスを取り出す構成が開示されているが、このような構成とすると、ワイヤーハーネスをプレス成形するごとに金型の加熱と冷却を行う必要がある。このため、ワイヤーハーネスの製造に要する時間が長くなる。   Moreover, although the structure which takes out a wire harness after cooling a metal mold | die is disclosed by patent document 1, when it is set as such a structure, whenever a wire harness is press-molded, a metal mold | die is heated and cooled. There is a need. For this reason, the time which manufactures a wire harness becomes long.

さらに、成形後や冷却後において、プロテクタや被覆材の軸線形状を変更しようとすると、プロテクタや被覆材が損傷するおそれがある。また、プロテクタや被覆材の剛性が高い場合には、軸線形状を変更することができない。   Furthermore, if the axial shape of the protector or the covering material is changed after molding or cooling, the protector or the covering material may be damaged. Moreover, when the rigidity of the protector or the covering material is high, the axial shape cannot be changed.

なお、電線の軸線形状を所定の形状に成形する方法としては、電線にテープを巻き付ける方法がある。すなわち、電線にテープを巻き付けることによって、複数の電線を結束するとともに、結束した電線が所定の軸線形状を有するようにする。しかしながら、このような方法では、テープを巻き付ける作業に手間と時間を要する。また、テープが巻き付けられた構成は、見映えがよくない。さらに、手作業でテープを巻き付ける方法であると、形状が変形するなど品質にばらつきが生じるおそれがある。   In addition, there exists a method of winding a tape around an electric wire as a method of forming the axial shape of the electric wire into a predetermined shape. That is, a plurality of electric wires are bundled by winding a tape around the electric wires, and the bundled electric wires have a predetermined axial shape. However, such a method requires time and effort for winding the tape. Also, the configuration in which the tape is wound does not look good. Furthermore, if the tape is wound manually, the quality may vary due to deformation of the shape.

なお、電線に射出成形品を装着する構成においては、ワイヤーハーネスの所定の部分が三次元的な形状を有する場合には、射出成形型の設計が難しくなり、設備コストが上昇する。   In addition, in the structure which mounts an injection molded product on an electric wire, when the predetermined part of a wire harness has a three-dimensional shape, design of an injection mold becomes difficult and equipment cost rises.

特開2003−197038号公報Japanese Patent Laid-Open No. 2003-197038

上記実情に鑑み、本発明が解決しようとする課題は、射出成形品の形状維持部材やプロテクタを用いることなく、電線や電線束を所定の形状に維持する形状維持部材や電線や電線束を保護するプロテクタを有するワイヤーハーネスの製造方法を提供すること、または、形状維持部材やプロテクタの製造コストや製造工数の削減を図ることができるワイヤーハーネスの製造方法を提供すること、または、形状維持部材やプロテクタの軸線形状を所定の形状に成形することが容易なワイヤーハーネスの製造方法を提供すること、または、熱可塑性材料からなる形状維持部材やプロテクタを有するワイヤーハーネスを製造するに際し、熱可塑性材料に不測の変形が発生しないようにできるワイヤーハーネスの製造方法を提供すること、または、熱可塑性材料からなる形状維持部材やプロテクタを有するワイヤーハーネスを製造するに際し、形状維持部材やプロテクタの軸線形状を所定の形状に成形することが容易なワイヤーハーネスの製造方法を提供すること、または、熱可塑性材料からなる形状維持部材やプロテクタを有するワイヤーハーネスを製造するに際し、製造に要する時間の短縮を図ることができるワイヤーハーネスの製造方法を提供することができるワイヤーハーネスの製造方法を提供することである。   In view of the above circumstances, the problem to be solved by the present invention is to protect the shape maintaining member, the electric wire and the electric wire bundle which maintain the electric wire and the electric wire bundle in a predetermined shape without using the shape maintaining member and the protector of the injection molded product. Providing a manufacturing method of a wire harness having a protector, or providing a manufacturing method of a wire harness capable of reducing the manufacturing cost and manufacturing man-hours of a shape maintaining member and a protector, or a shape maintaining member, To provide a method for manufacturing a wire harness that can easily form the protector's axial shape into a predetermined shape, or to manufacture a wire harness having a shape maintaining member or a protector made of a thermoplastic material. Providing a method of manufacturing a wire harness that can prevent unexpected deformation or heat When manufacturing a wire harness having a shape maintaining member and a protector made of a conductive material, it is possible to provide a method for manufacturing a wire harness that is easy to form the axial shape of the shape maintaining member and the protector into a predetermined shape, or heat Providing a method for manufacturing a wire harness that can provide a method for manufacturing a wire harness that can reduce the time required for manufacturing when manufacturing a wire harness having a shape maintaining member and a protector made of a plastic material. is there.

記課題を解決するため本発明は、電線の所定の部分が熱可塑性の材料からなる不織布に覆われたワイヤーハーネスの製造方法であって、電線の周囲に熱可塑性の材料からなる不織布で覆うとともに、前記熱可塑性の材料からなる不織布を熱可塑性による塑性変形が可能な温度に加熱するとともに加圧して所定の断面形状および寸法に成形する第一の工程と、前記第一の工程の後、前記熱可塑性の材料からなる不織布が熱可塑性による塑性変形が可能な温度にあるうちに前記熱可塑性材料を所定の軸線形状に成形し、所定の軸線形状に成形した状態で冷却する第二の工程と、を含み、前記不織布は、基本繊維とバインダ繊維とを有し、前記基本繊維は、所定の融点を有する熱可塑性の樹脂材料からなり、前記バインダ繊維は、芯繊維と前記芯繊維の外周に成形されるバインダ材の層とを有し、前記芯繊維は所定の融点を有する熱可塑性の樹脂材料からなり、前記バインダ材の層は前記基本繊維および前記芯繊維の融点よりも低い融点の熱可塑性の樹脂材料からなることを要旨とするものである。 To solve the previous SL object, the present invention is predetermined part of the wires is a method for producing a wire harness covered with nonwoven fabric made of thermoplastic material, a nonwoven fabric made of a thermoplastic material around the wires A first step of covering and heating the nonwoven fabric made of the thermoplastic material to a temperature capable of plastic deformation by thermoplasticity and pressurizing to form a predetermined cross-sectional shape and dimensions; and after the first step Second, the thermoplastic material is molded into a predetermined axial shape while the nonwoven fabric made of the thermoplastic material is at a temperature at which plastic deformation due to thermoplasticity is possible, and cooled in a state of being molded into the predetermined axial shape. includes a step, wherein the nonwoven fabric has a basic fibers and binder fibers, wherein the base fibers is made of a thermoplastic resin material having a predetermined melting point, said binder fibers, said the fiber core A binder material layer formed on the outer periphery of the fiber, the core fiber is made of a thermoplastic resin material having a predetermined melting point, and the binder material layer has a melting point of the basic fiber and the core fiber. It consists of a thermoplastic resin material having a low melting point .

また、別の本発明では、電線の所定の部分を覆う部材が、熱可塑性の材料からなる不織布により成形される。したがって、電線の所定の部分を覆う部材は、空気を多く含む層となる。このような空気を多く含む層は、空気によって断熱性が向上するから、冷めにくい。そのため、別の本発明によれば、(電線の所定の部分を覆う部材がひとかたまり(バルク)であるような場合と比較して、)電線の所定の部分を覆う熱可塑性の材料(不織布)を加熱および加圧してから、所定の軸線形状に成形するまでの間当該所定の部分を覆う部材が冷めにくく、電線の所定の部分を覆う熱可塑性の材料(不織布)を所定の軸線形状にする作業が容易となる。   In another aspect of the present invention, a member covering a predetermined portion of the electric wire is formed of a nonwoven fabric made of a thermoplastic material. Therefore, the member covering the predetermined part of the electric wire becomes a layer containing a lot of air. Such a layer containing a large amount of air is hard to cool because the heat insulation is improved by the air. Therefore, according to another aspect of the present invention, a thermoplastic material (nonwoven fabric) covering a predetermined portion of the electric wire (as compared to a case where the member covering the predetermined portion of the electric wire is a bulk (bulk)) The process of making the thermoplastic material (nonwoven fabric) covering the predetermined portion of the electric wire into the predetermined axial shape is difficult to cool the member covering the predetermined portion from the heating and pressurization until it is molded into the predetermined axial shape. Becomes easy.

本発明の実施形態にかかるワイヤーハーネスの製造方法を用いて製造されるワイヤーハーネスのうちの所定の部分(=所定の形状に成形された形状維持部材が設けられる部分)を抜き出して示した外観斜視図である。FIG. 3 is an external perspective view showing a predetermined portion (= portion where a shape maintaining member formed in a predetermined shape is provided) of a wire harness manufactured using the method for manufacturing a wire harness according to an embodiment of the present invention. FIG. 下型保持具と第一の成形型の下型の要部の構成を模式的に示した外観斜視図である。It is the external appearance perspective view which showed typically the structure of the principal part of a lower mold | type holder and the lower mold of a 1st shaping | molding die. 第一の成形型の上型の要部の構成を模式的に示した外観斜視図である。It is the external appearance perspective view which showed typically the structure of the principal part of the upper mold | type of a 1st shaping | molding die. 第一の工程に含まれる所定の工程を模式的に示した断面図であり、被成形体により電線を包む工程を示した図である。It is sectional drawing which showed typically the predetermined | prescribed process included in a 1st process, and is the figure which showed the process of wrapping an electric wire with a to-be-molded body. 第一の工程に含まれる所定の工程を模式的に示した断面図であり、電線および被成形体を下側保持具に収容する工程を示した図である。It is sectional drawing which showed typically the predetermined | prescribed process included in a 1st process, and is the figure which showed the process of accommodating an electric wire and a to-be-molded body in a lower holder. 第一の工程に含まれる所定の工程を模式的に示した断面図であり、下側保持具を第一の成形型の下型の係合部に係合する工程を示した図である。It is sectional drawing which showed typically the predetermined | prescribed process included in a 1st process, and is the figure which showed the process of engaging a lower holding tool with the engaging part of the lower mold | type of a 1st shaping | molding die. 第一の工程に含まれる所定の工程を模式的に示した断面図であり、第一の成形型の上型と下型とにより被成形体を加熱および加圧成形している工程を示した図である。It is sectional drawing which showed typically the predetermined | prescribed process included in a 1st process, and showed the process of heating and press-molding a to-be-molded body with the upper mold | type and lower mold | type of a 1st shaping | molding die. FIG. 第一の工程に含まれる所定の工程を模式的に示した断面図であり、電線および所定の断面形状に成形された形状維持部材を、第一の成形型の上型および下型から取り外す工程を示した図である。It is sectional drawing which showed typically the predetermined | prescribed process included in a 1st process, and removes the shape maintenance member shape | molded by the electric wire and predetermined | prescribed cross-sectional shape from the upper mold | type and lower mold | type of a 1st shaping | molding die FIG. 第一の工程を経た本ワイヤーハーネスの所定の部分を抜き出して示した外観斜視図である。It is the external appearance perspective view which extracted and showed the predetermined part of this wire harness which passed through the 1st process. 第二の成形型の構成を、模式的に示した分解斜視図である。It is the disassembled perspective view which showed the structure of the 2nd shaping | molding die typically. 被成形体が熱可塑性の材料からなる不織布により成形された形状維持部材の断面写真である。It is a cross-sectional photograph of a shape maintaining member formed by a non-woven fabric made of a thermoplastic material.

以下に、本発明の実施形態について、図面を参照して詳細に説明する。   Embodiments of the present invention will be described below in detail with reference to the drawings.

図1は、本発明の実施形態にかかるワイヤーハーネスの製造方法を用いて製造されるワイヤーハーネス1のうちの所定の部分(=所定の形状に成形された形状維持部材12が設けられる部分)を抜き出して示した外観斜視図である。なお、説明の便宜上、本発明の実施形態にかかるワイヤーハーネスの製造方法を用いて製造されるワイヤーハーネス1を、「本ワイヤーハーネス1」と称することがある。   FIG. 1 shows a predetermined portion (= portion where a shape maintaining member 12 formed in a predetermined shape is provided) of a wire harness 1 manufactured using the method of manufacturing a wire harness according to an embodiment of the present invention. It is the external appearance perspective view extracted and shown. For convenience of explanation, the wire harness 1 manufactured using the method for manufacturing a wire harness according to the embodiment of the present invention may be referred to as “the present wire harness 1”.

本ワイヤーハーネス1は、全体として、所定の種類および所定の数の電線11を備え、これらの電線11が所定の態様で纏められる(または結束される)構成を備える。そして、束ねられた(または結束された)電線11が、本ワイヤーハーネス1の幹線や枝線を形成する。本ワイヤーハーネス1に含まれる各電線11の端部には、所定の種類のコネクタ類が装着される。なお、本ワイヤーハーネス1に含まれる電線11の種類や数、本ワイヤーハーネス1の全体的な形状(たとえば、幹線や枝線の形状、枝線の数や分岐形態など)や、各電線11に装着されるコネクタ類の構成などは、必要に応じて適宜設定されるものであり、限定されるものではない。なお、本発明において単に「電線」と記す場合には、単数の電線を意味するほか、複数の電線(すなわち、本ワイヤーハーネスの幹線や枝線)も含むものとする。   The wire harness 1 as a whole includes a predetermined type and a predetermined number of electric wires 11 and a configuration in which these electric wires 11 are bundled (or bound) in a predetermined manner. Then, the bundled (or bundled) electric wires 11 form a trunk line or a branch line of the wire harness 1. A predetermined type of connectors is attached to the end of each electric wire 11 included in the wire harness 1. In addition, the kind and number of the electric wires 11 included in the wire harness 1, the overall shape of the wire harness 1 (for example, the shape of the trunk line or branch line, the number of branch lines, the branch form, etc.) The configuration of the connectors to be mounted is appropriately set as necessary, and is not limited. In the present invention, the simple description of “electric wire” means a single electric wire and also includes a plurality of electric wires (that is, trunk wires and branch wires of the wire harness).

図1に示すように、本ワイヤーハーネス11の所定の部分には、形状維持部材12が設けられる。すなわち、本ワイヤーハーネス1の所定の部分は、電線11と、形状維持部材12とを備え、電線11が形状維持部材12に覆われる構成を有する。形状維持部材12は、電線11を所定の形状に維持する機能(特に、電線11の軸線を所定の形状に維持する機能)を有するほか、電線11を保護する機能(いわゆる「プロテクタ」としての機能)も有する。本ワイヤーハーネス1のうち、形状維持部材12が設けられる部分(=本発明にいう本ワイヤーハーネス1の所定の部分)の位置や範囲は、特に限定されるものではなく、電線11の軸線を所定の形状に維持したい部分や、電線11を保護したい部分に適宜設けられる。   As shown in FIG. 1, a shape maintaining member 12 is provided in a predetermined portion of the wire harness 11. That is, the predetermined part of the wire harness 1 includes the electric wire 11 and the shape maintaining member 12, and the electric wire 11 is covered with the shape maintaining member 12. The shape maintaining member 12 has a function of maintaining the electric wire 11 in a predetermined shape (particularly a function of maintaining the axis of the electric wire 11 in a predetermined shape), and a function of protecting the electric wire 11 (a function as a so-called “protector”). ). The position and range of the portion (= predetermined portion of the wire harness 1 according to the present invention) where the shape maintaining member 12 is provided in the wire harness 1 are not particularly limited, and the axis of the electric wire 11 is predetermined. It is suitably provided in a portion where it is desired to maintain the shape of the wire and a portion where the electric wire 11 is desired to be protected.

形状維持部材12の断面の形状および寸法や、軸線の形状は、本ワイヤーハーネス1が配索される領域の空間の形状などに応じて適宜設定される。たとえば、本ワイヤーハーネス1の所定の部分は、当該所定の部分が配索される領域の空間の形状および寸法に略同じ形状および寸法に形成される構成や、配索に便利な形状に形成される構成が適用できる。このように、形状維持部材12の断面形状および寸法や、軸線の形状は、特に限定されるものではない。   The shape and dimensions of the cross section of the shape maintaining member 12 and the shape of the axis are appropriately set according to the shape of the space in the area where the wire harness 1 is routed. For example, the predetermined portion of the wire harness 1 is formed in a configuration that is formed in a shape and size that is substantially the same as the shape and size of the space of the region in which the predetermined portion is routed, or a shape that is convenient for routing. Can be applied. Thus, the cross-sectional shape and dimension of the shape maintaining member 12 and the shape of the axis are not particularly limited.

形状維持部材12は、熱可塑性を有し、弾性変形可能な材料(特に、見かけ上の体積が小さくなるような圧縮変形が可能な材料)により形成される。たとえば、熱可塑性の樹脂材料などからなる不織布や、発泡体などにより形成される。なお、説明の便宜上、形状維持部材12の材料となる部材を、「被成形体」13と称する。   The shape maintaining member 12 is made of a thermoplastic material that can be elastically deformed (particularly, a material that can be compressed and deformed so that the apparent volume is reduced). For example, it is formed of a nonwoven fabric made of a thermoplastic resin material or the like, or a foam. For convenience of explanation, a member that is a material of the shape maintaining member 12 is referred to as a “molded body” 13.

被成形体13としての不織布には、基本繊維とバインダ繊維とが絡み合った構成を有するものが適用できる。基本繊維は、所定の融点を有する熱可塑性樹脂材料により形成される。バインダ繊維は、芯繊維の外周にバインダ材の層が形成される構成を有する。芯繊維は、基本繊維と同じ熱可塑性樹脂材料により形成される。バインダ材の層は、基本繊維および芯繊維よりも融点が低い熱可塑性樹脂材料により形成される。なお、このような構成の不織布を、説明の便宜上、「第一の不織布」と称する。   As the non-woven fabric as the molded body 13, one having a configuration in which basic fibers and binder fibers are intertwined can be applied. The basic fiber is formed of a thermoplastic resin material having a predetermined melting point. The binder fiber has a configuration in which a binder material layer is formed on the outer periphery of the core fiber. The core fiber is formed of the same thermoplastic resin material as the basic fiber. The binder material layer is formed of a thermoplastic resin material having a melting point lower than that of the basic fiber and the core fiber. In addition, the nonwoven fabric of such a structure is called "a 1st nonwoven fabric" for convenience of explanation.

第一の不織布は、ある所定の温度以上の温度に加熱されると、基本繊維およびバインダ繊維が有する熱可塑性により、塑性変形しやすい状態となる。特に、バインダ繊維のバインダ材の融点よりも高い温度であって、基本繊維およびバインダ繊維の芯繊維の融点よりも低い温度帯域に加熱されると、基本繊維およびバインダ繊維の芯繊維は、固体の状態(=繊維の状態)を維持したままで熱可塑性により塑性変形できるようになる。一方、この温度帯域に加熱されると、バインダ繊維のバインダ材は溶融して、基本繊維およびバインダ繊維の芯繊維の間に流出する。このため、その後、バインダ材の融点よりも低い温度に戻ると、バインダ材が固体の状態に戻り、接着剤(またはホットメルト樹脂)のような態様で、基本繊維およびバインダ繊維の芯繊維どうしを結合する。   When the first nonwoven fabric is heated to a temperature equal to or higher than a predetermined temperature, the first nonwoven fabric is easily plastically deformed due to the thermoplasticity of the basic fiber and the binder fiber. In particular, when heated to a temperature range higher than the melting point of the binder material of the binder fiber and lower than the melting point of the core fiber of the base fiber and the binder fiber, the core fiber of the base fiber and the binder fiber are solid. It can be plastically deformed by thermoplasticity while maintaining the state (= fiber state). On the other hand, when heated to this temperature range, the binder material of the binder fiber melts and flows out between the basic fiber and the core fiber of the binder fiber. For this reason, after that, when the temperature returns to a temperature lower than the melting point of the binder material, the binder material returns to a solid state, and the core fibers and the core fibers of the binder fibers are bonded in a manner like an adhesive (or hot melt resin). Join.

したがって、第一の不織布が、バインダ繊維のバインダ材の融点よりも高い温度であって基本繊維およびバインダ繊維の芯繊維の融点よりも低い温度帯域に加熱され、この温度帯域で所定の形状に形成され、その後、基本繊維およびバインダ繊維が熱可塑性による塑性変形をしない温度に冷却されると、前記温度帯域において成形された形状を維持する。さらに、溶融したバインダ材が固化して基本繊維やバインダ繊維の芯繊維どうしを結合するため、加熱前に比較して硬くなる。   Therefore, the first nonwoven fabric is heated to a temperature range higher than the melting point of the binder material of the binder fiber and lower than the melting point of the core fiber of the basic fiber and the binder fiber, and is formed into a predetermined shape in this temperature range. After that, when the base fiber and the binder fiber are cooled to a temperature at which plastic deformation does not occur due to thermoplasticity, the shape formed in the temperature band is maintained. Furthermore, since the molten binder material is solidified and bonds the core fibers and the core fibers of the binder fibers, it becomes harder than before heating.

なお、説明の便宜上、基本繊維およびバインダ繊維が熱可塑性によって塑性変形しやすくなる温度帯域を、第一の不織布の「第一の可塑化温度帯域」と称し、第一の不織布の「第一の可塑化温度帯域」のうち、バインダ繊維のバインダ材の融点以上の温度であって基本繊維およびバインダ繊維の芯繊維の融点よりも低い温度帯域を、第一の不織布の「第二の可塑化温度帯域」と称する。   For convenience of explanation, the temperature zone in which the basic fiber and the binder fiber are easily plastically deformed by thermoplasticity is referred to as the “first plasticization temperature zone” of the first nonwoven fabric, Among the “plasticization temperature zone”, a temperature zone that is equal to or higher than the melting point of the binder material of the binder fiber and lower than the melting point of the core fiber of the basic fiber and the binder fiber is referred to as the “second plasticization temperature of the first nonwoven fabric”. This is called “bandwidth”.

第一の不織布の基本繊維には、PET(ポリエチレンテレフタレート)からなる繊維が適用できる。第一の不織布のバインダ繊維には、PETにより形成される芯繊維と、PETとPEI(ポリエチレンイソフタレート)の共重合樹脂により形成されるバインダ材の層とを有し、芯繊維の外周にバインダ材の層が形成される構成の繊維が適用できる。このような構成の不織布の基本繊維や芯繊維(すなわちPET)の融点は、約250℃である。バインダ材の融点は110〜150℃である。したがって、この第一の不織布の第二の可塑化温度帯域は110〜250℃である。   A fiber made of PET (polyethylene terephthalate) can be applied to the basic fiber of the first nonwoven fabric. The binder fiber of the first nonwoven fabric has a core fiber formed of PET and a binder material layer formed of a copolymer resin of PET and PEI (polyethylene isophthalate). A fiber having a structure in which a layer of material is formed can be applied. The melting point of the basic fiber and the core fiber (that is, PET) of the nonwoven fabric having such a configuration is about 250 ° C. The melting point of the binder material is 110 to 150 ° C. Therefore, the second plasticizing temperature zone of the first nonwoven fabric is 110 to 250 ° C.

このほか、被成形体13には、バインダ繊維を有しない熱可塑性樹脂材料からなる不織布も適用できる。このような不織布を、説明の便宜上、「第二の不織布」と称して区別する。たとえば、PETからなる不織布が適用できる。また、被成形体13には、熱可塑性材料からなる発泡体も適用できる。たとえば、PETからなる発泡体が適用できる。被成形体13に適用される第二の不織布および発泡体は、それらの材料である熱可塑性樹脂材料の融点より低い温度であって融点近傍の温度に加熱されると、熱可塑性により塑性変形しやすくなる。   In addition, the nonwoven fabric which consists of a thermoplastic resin material which does not have a binder fiber is also applicable to the to-be-molded body 13. Such a non-woven fabric is referred to as a “second non-woven fabric” for convenience of explanation. For example, a nonwoven fabric made of PET can be applied. A foam made of a thermoplastic material can also be applied to the molded body 13. For example, a foam made of PET can be applied. When the second nonwoven fabric and the foam applied to the molded body 13 are heated to a temperature lower than the melting point of the thermoplastic resin material which is their material and close to the melting point, they are plastically deformed due to thermoplasticity. It becomes easy.

形状維持部材12の表層部(=外表面およびその近傍)は、中心部(=電線11の所定の部分に接触している部分およびその近傍)に比較して硬く形成される。具体的には、形状維持部材12の表層部は、本発明の実施形態にかかるワイヤーハーネスの製造方法によって形状維持部材12に成形される前の被成形体13よりも硬さが硬い。そして、この硬い表層部は、電線11の所定の部分の軸線を所定の形状に維持する機能を有するとともに、電線11の所定の部分を保護する機能を有する。   The surface layer portion (= outer surface and its vicinity) of the shape maintaining member 12 is formed harder than the center portion (= the portion in contact with a predetermined portion of the electric wire 11 and its vicinity). Specifically, the surface layer portion of the shape maintaining member 12 is harder than the molded body 13 before being formed into the shape maintaining member 12 by the wire harness manufacturing method according to the embodiment of the present invention. And this hard surface layer part has a function which protects the predetermined part of the electric wire 11, while maintaining the axis of the predetermined part of the electric wire 11 in a predetermined shape.

一方、形状維持部材12の中心部は、表層部に比較して軟らかく形成される。具体的には、形状維持部材12の中心部は、形状維持部材12に成形される前の被成形体13の性質を、表層部に比較して多く有している。そして、形状維持部材12の中心部は、電線11の所定の部分に弾性的に接触して包み込んでおり、電線11の所定の部分を衝撃や振動などから保護する機能を有する。さらに、形状維持部材12の中心部は、防音材としての機能も有する。すなわち、形状維持部材12が、弾性を有する状態で電線11の所定の部分に接触して包みこんでいるため、本ワイヤーハーネス1に振動や外力が加わった場合であっても、電線11に振動や外力が伝達することを防止または抑制する。また、電線11と形状維持部材12とが弾性的に接触しているから、これらの間で衝突音などの発生が防止される。   On the other hand, the central portion of the shape maintaining member 12 is formed softer than the surface layer portion. Specifically, the central portion of the shape maintaining member 12 has more properties of the molded body 13 before being molded into the shape maintaining member 12 than the surface layer portion. The central portion of the shape maintaining member 12 is wrapped in contact with a predetermined portion of the electric wire 11 in an elastic manner, and has a function of protecting the predetermined portion of the electric wire 11 from impact or vibration. Further, the central portion of the shape maintaining member 12 also has a function as a soundproof material. That is, since the shape maintaining member 12 wraps in contact with a predetermined portion of the electric wire 11 in an elastic state, the electric wire 11 vibrates even when vibration or external force is applied to the wire harness 1. Prevent or suppress the transmission of external force. Moreover, since the electric wire 11 and the shape maintaining member 12 are in elastic contact with each other, occurrence of a collision sound or the like is prevented between them.

次に、本発明の実施形態にかかるワイヤーハーネスの製造方法について説明する。本発明の実施形態にかかるワイヤーハーネスの製造方法は、本ワイヤーハーネス1を構成する電線11の所定の部分を形状維持部材12で覆う工程(=電線11の周囲に形状維持部材12を形成する工程)と、形状維持部材12を所定の形状の軸線に成形する工程とを含む。説明の便宜上、電線11の所定の部分を形状維持部材12で覆う工程を「第一の工程」と称し、形状維持部材12を所定の形状の軸線に成形する工程を「第二の工程」と称する。   Next, the manufacturing method of the wire harness concerning embodiment of this invention is demonstrated. The manufacturing method of the wire harness according to the embodiment of the present invention includes a step of covering a predetermined portion of the electric wire 11 constituting the wire harness 1 with the shape maintaining member 12 (= a step of forming the shape maintaining member 12 around the electric wire 11. And a step of forming the shape maintaining member 12 into an axis of a predetermined shape. For convenience of explanation, a process of covering a predetermined portion of the electric wire 11 with the shape maintaining member 12 is referred to as a “first process”, and a process of forming the shape maintaining member 12 into an axis of a predetermined shape is referred to as a “second process”. Called.

第一の工程の内容は次のとおりである。   The contents of the first step are as follows.

第一の工程においては、第一の成形型5と下側保持具62とが用いられる。第一の成形型5は、一対となる上型51と下型52(たとえば、いずれも金型が適用できる)を有する。図2は、下型保持具62と第一の成形型5の下型52の要部の構成を模式的に示した外観斜視図である。図3は、第一の成形型5の上型51の要部の構成を模式的に示した外観斜視図である。下側保持具62および第一の成形型5の下型52については、図2中の上方が、第一の成形型5の上型51に対向する側となる。第一の成形型5の上型51については、図3の上方が、下側保持具62および第一の成形型5の下型52に対向する側となる。説明の便宜上、下側保持具62と第一の成形型5の下型52については、第一の成形型5の上型51に対向する側を「上側」と称し、第一の成形型5の上型51については、下側保持具62および第一の成形型5の下型52に対向する側を「下側」と称する。図2においては、図中の上方が上側であり、図3においては、図中の上方が下側である。   In the first step, the first mold 5 and the lower holder 62 are used. The first mold 5 includes a pair of an upper mold 51 and a lower mold 52 (for example, a mold can be applied to both). FIG. 2 is an external perspective view schematically showing the configuration of the main parts of the lower mold holder 62 and the lower mold 52 of the first mold 5. FIG. 3 is an external perspective view schematically showing the configuration of the main part of the upper mold 51 of the first mold 5. Regarding the lower holder 62 and the lower mold 52 of the first mold 5, the upper side in FIG. 2 is the side facing the upper mold 51 of the first mold 5. With respect to the upper mold 51 of the first mold 5, the upper side in FIG. 3 is the side facing the lower holder 62 and the lower mold 52 of the first mold 5. For convenience of explanation, for the lower holder 62 and the lower mold 52 of the first mold 5, the side facing the upper mold 51 of the first mold 5 is referred to as “upper side”, and the first mold 5 For the upper mold 51, the side facing the lower holder 62 and the lower mold 52 of the first mold 5 is referred to as “lower side”. In FIG. 2, the upper side in the figure is the upper side, and in FIG. 3, the upper side in the figure is the lower side.

下側保持具62は、第一の工程において、被成形体13を加圧して所定の形状および寸法を有する形状維持部材12に成形する機能や、所定の形状および寸法に成形された形状維持部材12(=成形後の被成形体13)を所定の形状および寸法に維持する(換言すると、形状維持部材12が、不測の変形または望まない変形をしないようにする)などの機能を有する工具(または治具)である。   In the first step, the lower holding tool 62 has a function of pressurizing the molded body 13 to form the shape maintaining member 12 having a predetermined shape and size, and a shape maintaining member formed into a predetermined shape and size. 12 (= molded body 13 after molding) is maintained in a predetermined shape and dimensions (in other words, the shape maintaining member 12 is prevented from unexpected deformation or undesired deformation) ( Or a jig).

下側保持具62は、上側に向かって開放する溝状の凹部623を有する。具体的には、下側保持具62は、所定の幅寸法を有し所定の軸線方向に延伸する底部621と、底部621の軸線方向の両側部から上側に向かって起立する壁部622とを有する。そして、底部621の上側の面と両側の壁部622の内側の面とに囲繞される領域が、上側に向かって開放する溝状の凹部623となる。したがって、下側保持具62は、全体として、断面が略「U」字形状の棒状の構造を有する。   The lower holding tool 62 has a groove-shaped recess 623 that opens upward. Specifically, the lower holding tool 62 includes a bottom portion 621 having a predetermined width dimension and extending in a predetermined axial direction, and a wall portion 622 erected upward from both sides in the axial direction of the bottom portion 621. Have. A region surrounded by the upper surface of the bottom portion 621 and the inner surfaces of the wall portions 622 on both sides is a groove-shaped recess 623 that opens upward. Therefore, the lower holder 62 as a whole has a rod-like structure having a substantially “U” cross section.

溝状の凹部623の底部近傍(=底部621の上側の面、または底部621の上側の面と壁部622の内側の面の底部近傍。被成形体13を加圧している状態において、被成形体13に接触する部分を指す)の断面形状(ここでは、下側保持具62を軸線方向に直角な方向で切断した場合における断面形状をいう)は、成形する形状維持部材12の断面の形状および寸法に応じた形状および寸法に設定される。たとえば、形状維持部材12を略円形の断面形状に形成する場合には、底部621の上側の面は略半円に形成される。また、形状維持部材12を、略四辺形の断面形状に形成する場合には、底部621の上側の面と両側の壁部622の内側の面は、それらに囲まれる領域の断面形状が略四辺形となるように形成される。すなわち、底部621の上面が略平面に形成されるとともに、両側の壁部622の少なくとも底部621近傍の部分が略平面に形成され、両側の壁部622の少なくとも底部621の近傍が底部621の上側の面に対して略直角に起立する。   Near the bottom of the groove-shaped recess 623 (= the upper surface of the bottom 621, or near the bottom of the upper surface of the bottom 621 and the inner surface of the wall 622. In the state where the molding 13 is being pressed, the molding is performed. The cross-sectional shape of the shape maintaining member 12 to be molded is the cross-sectional shape of the shape maintaining member 12 to be molded (referred to here as the cross-sectional shape when the lower holder 62 is cut in a direction perpendicular to the axial direction). And a shape and size corresponding to the size. For example, when the shape maintaining member 12 is formed in a substantially circular cross-sectional shape, the upper surface of the bottom 621 is formed in a substantially semicircle. Further, when the shape maintaining member 12 is formed to have a substantially quadrangular cross-sectional shape, the cross-sectional shape of the region surrounded by the upper surface of the bottom 621 and the inner surfaces of the wall portions 622 on both sides is substantially quadrilateral. It is formed to be in shape. That is, the upper surface of the bottom portion 621 is formed in a substantially flat surface, and at least a portion in the vicinity of the bottom portion 621 of the wall portions 622 on both sides is formed in a substantially flat surface. Stands at a right angle to the surface of

下側保持具62は、熱伝導率の高い材料により形成され、蓄熱量が小さい(すなわち、周りの温度変化に追従しやすい)構成を有する。特に、溝状の凹部623の内側と外側との間で熱を伝えやすい構成を有する。具体的にはたとえば、薄い金属板などからなり、板金加工などにより形成される。薄い金属板などからなれば、金属板の厚さ方向に熱を伝えやすく、かつ、下側保持具62の質量を小さくできるから、蓄熱量を小さくすることができる。また、底部621と壁部622とは、一枚の金属板に鈑金加工などを施すことにより一体に形成される。底部621と壁部622とが一枚の金属板などから一体に形成される構成であれば、別体からなる部品を組み付ける必要がない。このため、別体からなる部品を組み付ける構成に比較すると、下側保持具62の部品コストや製造コストの上昇を防止することができる。さらに下側保持具62の製造の手間を削減することができる。   The lower holding tool 62 is formed of a material having high thermal conductivity, and has a configuration in which the amount of heat storage is small (that is, it can easily follow the surrounding temperature change). In particular, it has a configuration in which heat can be easily transferred between the inside and the outside of the groove-like recess 623. Specifically, for example, it is made of a thin metal plate or the like, and is formed by sheet metal processing or the like. If it consists of a thin metal plate etc., since heat can be easily transmitted to the thickness direction of a metal plate and the mass of the lower holding | maintenance tool 62 can be made small, a heat storage amount can be made small. Further, the bottom portion 621 and the wall portion 622 are integrally formed by performing a plating process or the like on a single metal plate. If the bottom 621 and the wall 622 are formed integrally from a single metal plate or the like, there is no need to assemble separate parts. For this reason, compared with the structure which assembles | assembles the component which consists of another body, the raise of the component cost and manufacturing cost of the lower side holder 62 can be prevented. Furthermore, labor for manufacturing the lower holding tool 62 can be reduced.

下側保持具62の溝状の凹部623の外側の面の形状(=底部621の下側の面の形状、および壁部622の外側の面の形状)は、特に限定されるものではない。下側保持具62が薄板などからなり、鈑金加工などにより形成される場合には、下側保持具62の底部621の下側の面の形状、および壁部622の外側の面の形状は、底部621の上側の面の形状および壁部622の内側の面の形状に略相似な形状となる。   The shape of the outer surface of the groove-shaped recess 623 of the lower holding tool 62 (= the shape of the lower surface of the bottom portion 621 and the shape of the outer surface of the wall portion 622) is not particularly limited. When the lower holder 62 is made of a thin plate or the like and is formed by plating or the like, the shape of the lower surface of the bottom 621 of the lower holder 62 and the shape of the outer surface of the wall 622 are: The shape is substantially similar to the shape of the upper surface of the bottom portion 621 and the shape of the inner surface of the wall portion 622.

第一の成形型5の下型52は、下側保持具62を介して、第一の成形型5の上型51とともに被成形体13を加熱しながら加圧し、形状維持部材12を成形する工具である。すなわち、熱可塑性を利用して被成形体13を塑性変形させ、所定の断面形状および寸法を有する形状維持部材12に形成する。   The lower mold 52 of the first mold 5 is pressed while heating the molded body 13 together with the upper mold 51 of the first mold 5 via the lower holder 62 to mold the shape maintaining member 12. It is a tool. That is, the molded body 13 is plastically deformed using thermoplasticity, and formed into the shape maintaining member 12 having a predetermined cross-sectional shape and dimensions.

第一の成形型5の下型52の上側には、係合部521が形成される。係合部521は、上側に向かって開放する溝状の凹部であり、下側保持具62の全体または下側の一部(底部621および壁部622の底部621の近傍)を収容可能な構成を有する。図2においては、下側保持具62の下側の一部を収容可能な構成を示す。そして、下側保持具62を係合部521に係合させることによって、第一の成形型5の下型52の上側に、下側保持具62の溝状の凹部623の開放側を上側に向けて(=第一の成形型5の上型51に向けて)載置することができる。   An engaging portion 521 is formed on the upper side of the lower mold 52 of the first mold 5. The engaging portion 521 is a groove-shaped recess that opens upward, and can accommodate the entire lower holder 62 or a part of the lower portion (near the bottom portion 621 and the bottom portion 621 of the wall portion 622). Have In FIG. 2, the structure which can accommodate a part of lower side of the lower holder 62 is shown. Then, by engaging the lower holding tool 62 with the engaging portion 521, the upper side of the lower mold 52 of the first mold 5 and the open side of the groove-shaped recess 623 of the lower holding tool 62 are set to the upper side. It can be placed (= towards the upper mold 51 of the first mold 5).

第一の成形型5の下型52の係合部521の形状および寸法は、下側保持具62を係合部521に係合させた状態において、係合部521の表面が、下側保持具62の外側の表面のうちの係合部521に係合している部分(=下側保持具62の外側の面の略全体、または下側保持具62の底部621の下側の面および壁部622の外側の面の底部621の近傍)の略全体に接触することができるように設定される。   The shape and dimensions of the engaging portion 521 of the lower mold 52 of the first mold 5 are such that the surface of the engaging portion 521 is held on the lower side when the lower holding tool 62 is engaged with the engaging portion 521. Of the outer surface of the tool 62, the portion engaged with the engaging portion 521 (= the entire outer surface of the lower holding tool 62 or the lower surface of the bottom 621 of the lower holding tool 62 and It is set so as to be able to contact substantially the entire surface of the outer surface of the wall 622 (in the vicinity of the bottom 621).

たとえば、下側保持具62の外側の面(底部621の外側の面および壁部622の外側の面)の寸法および形状と略同じか、またはそれよりも少し大きい寸法および形状に設定される。したがって、図2に示すように、下側保持具62の底部621および側部622の底部621近傍の断面形状が略四辺形である場合には、係合部521の断面形状は略四辺形に設定される。また、下側保持具62の底部621の断面形状が略半円形状である場合には、係合部521の断面形状は略半円形状に設定されるか、または係合部521の底部が略半円状に設定される。   For example, the size and shape are set to be approximately the same as or slightly larger than the size and shape of the outer surface of the lower holder 62 (the outer surface of the bottom portion 621 and the outer surface of the wall portion 622). Therefore, as shown in FIG. 2, when the cross-sectional shape of the bottom portion 621 of the lower holding tool 62 and the vicinity of the bottom portion 621 of the side portion 622 is a substantially quadrilateral shape, the cross-sectional shape of the engaging portion 521 is a substantially quadrilateral shape. Is set. In addition, when the cross-sectional shape of the bottom portion 621 of the lower holding tool 62 is substantially semicircular, the cross-sectional shape of the engaging portion 521 is set to be substantially semicircular, or the bottom portion of the engaging portion 521 is It is set to a substantially semicircular shape.

第一の成形型5の下型52は、図略の加熱手段を備える。そして、この加熱手段により、係合部521の表面を所定の温度に維持することができる。なお、「所定の温度」については後述する。加熱手段には公知の各種加熱手段が適用できる。たとえば、加熱手段として電熱線が適用され、この電熱線が第一の成形型5の下型52の内部に埋め込まれる構成や、第一の成形型5の下型52の外周に電熱線が装着される構成が適用できる。また、第一の成形型5の下型52の内部に流体が通過することができる経路(たとえば孔)が形成され、この経路に温度調整された流体(温度調整された空気、液体(油など)、蒸気(過熱蒸気など))を通過させる構成が適用できる。このように、加熱手段は、第一の成形型5の下型52(特に係合部521の表面)を所定の温度に維持できる構成を有していればよく、その種類や構成は限定されるものではない。   The lower mold 52 of the first mold 5 includes heating means (not shown). And by this heating means, the surface of the engaging part 521 can be maintained at a predetermined temperature. The “predetermined temperature” will be described later. Various known heating means can be applied to the heating means. For example, a heating wire is applied as the heating means, and the heating wire is embedded in the lower mold 52 of the first mold 5 or the heating wire is attached to the outer periphery of the lower mold 52 of the first mold 5. The configuration to be applied is applicable. Further, a path (for example, a hole) through which a fluid can pass is formed inside the lower mold 52 of the first mold 5, and the temperature-adjusted fluid (temperature-adjusted air, liquid (oil, etc.) is formed in this path. ), Steam (such as superheated steam)) can be applied. Thus, the heating means only needs to have a configuration capable of maintaining the lower mold 52 (particularly the surface of the engaging portion 521) of the first mold 5 at a predetermined temperature, and the type and configuration thereof are limited. It is not something.

このように、第一の成形型5の下型52は、係合部521に係合された下側保持具62を所定の温度に加熱することができる。そして、係合部521の形状および寸法が前記のとおりであるから、下側保持具62のうちの係合部521に係合している部分を、略均一に加熱することができる。   Thus, the lower mold 52 of the first mold 5 can heat the lower holder 62 engaged with the engaging portion 521 to a predetermined temperature. And since the shape and dimension of the engaging part 521 are as above-mentioned, the part engaged with the engaging part 521 of the lower side holder 62 can be heated substantially uniformly.

第一の成形型5の上型51は、第一の成形型5の下型52および下側保持具62とともに、被成形体13を加熱しながら加圧することができる工具である。   The upper mold 51 of the first mold 5 is a tool capable of applying pressure while heating the molded body 13 together with the lower mold 52 and the lower holder 62 of the first mold 5.

第一の成形型5の上型51の下側の一部は、下側保持具62の壁部622どうしの間に嵌り込むことができる構成を有する。具体的には図3に示すように、第一の成形型5の上型51には、下側に向かって突起する凸状の構造物511が形成され、この凸状の構造物511の全部または下側の一部が、下側保持具62の壁部622どうしの間に嵌り込むことができる。このため、この凸状の構造物511の幅方向寸法(=軸線方向に直角な方向の寸法)は、下側保持具62の壁部622どうしの間の間隔と略同じか、またはそれよりも少し小さく設定される。   A part of the lower side of the upper mold 51 of the first mold 5 has a configuration that can be fitted between the wall portions 622 of the lower holding tool 62. Specifically, as shown in FIG. 3, the upper mold 51 of the first mold 5 is formed with a convex structure 511 that protrudes downward, and all of the convex structure 511 is formed. Alternatively, a part of the lower side can be fitted between the wall portions 622 of the lower holding tool 62. For this reason, the width-direction dimension (= dimension in the direction perpendicular to the axial direction) of the convex structure 511 is substantially the same as or larger than the interval between the wall portions 622 of the lower holder 62. Set a little smaller.

なお、図3に示すような構成のほか、第一の成形型5の上型51の全体が、下側保持具62の壁部622どうしの間に嵌り込むことができる寸法および形状に形成される構成であってもよい。   In addition to the configuration shown in FIG. 3, the entire upper mold 51 of the first mold 5 is formed in a size and shape that can be fitted between the wall portions 622 of the lower holding tool 62. It may be a configuration.

第一の成形型5の上型51の下側には、加圧面512が形成される。加圧面512は、被成形体13を加圧および加熱して、所定の断面形状を有する形状維持部材12を成形するための部分である。加圧面512は、第一の成形型5の下型52の係合部521に下側保持具62が係合された状態において、下側保持具62の底部621の上側の面に対向する。図3に示すように、第一の成形型5の上型51に下側に凸状の構造物511が形成される構成においては、当該凸状の構造物511の下側の面が加圧面512となる。一方、第一の成形型5の上型51の全体が、下側保持具62の側部どうしの間に嵌り込むことができる構成を有する場合には、第一の成形型5の上型51の下側の面の略全体が加圧面512となる。   A pressure surface 512 is formed on the lower side of the upper mold 51 of the first mold 5. The pressing surface 512 is a portion for pressing and heating the molded body 13 to form the shape maintaining member 12 having a predetermined cross-sectional shape. The pressure surface 512 faces the upper surface of the bottom 621 of the lower holder 62 in a state where the lower holder 62 is engaged with the engaging portion 521 of the lower mold 52 of the first mold 5. As shown in FIG. 3, in a configuration in which a convex structure 511 is formed on the lower side of the upper mold 51 of the first mold 5, the lower surface of the convex structure 511 is a pressure surface. 512. On the other hand, when the entire upper mold 51 of the first mold 5 has a configuration that can be fitted between the side portions of the lower holder 62, the upper mold 51 of the first mold 5. A substantially entire surface of the lower side is a pressure surface 512.

凸状の構造物511(または第一の成形型5の上型51の全体)の軸線方向に直角な面で切断した場合における加圧面512の断面形状および寸法は、成形する形状維持部材12の断面形状および寸法に応じて設定される。すなわち、加圧面512は、成形する形状維持部材12の外周面の一部の形状と略同じ形状に形成される。たとえば、形状維持部材12の断面形状が略四辺形の場合には、第一の成形型5の上型51の加圧面512は、略平面に形成される。また、形状維持部材12の断面形状が略円形である場合には、加圧面512は、断面略半円形状で上側に向かって窪む溝状の構成を有する。   The cross-sectional shape and dimensions of the pressing surface 512 when the convex structure 511 (or the entire upper mold 51 of the first mold 5) is cut along a plane perpendicular to the axial direction are the same as those of the shape maintaining member 12 to be molded. It is set according to the cross-sectional shape and dimensions. That is, the pressing surface 512 is formed in a shape that is substantially the same as the shape of a part of the outer peripheral surface of the shape maintaining member 12 to be molded. For example, when the cross-sectional shape of the shape maintaining member 12 is a substantially quadrilateral, the pressing surface 512 of the upper mold 51 of the first mold 5 is formed in a substantially flat surface. In addition, when the cross-sectional shape of the shape maintaining member 12 is substantially circular, the pressing surface 512 has a groove-like configuration that is substantially semicircular in cross section and is recessed upward.

第一の成形型5の上型51は、図略の加熱手段を備える。そして、この加熱手段により、特に加圧面512を、所定の温度に維持することができる。「所定の温度」は第一の成形型5の下型52と同じである。また、加熱手段も、第一の成形型5の下型52と同じ加熱手段が適用できる。したがって説明は省略する。   The upper mold 51 of the first mold 5 includes heating means (not shown). Then, in particular, the pressure surface 512 can be maintained at a predetermined temperature by this heating means. The “predetermined temperature” is the same as that of the lower mold 52 of the first mold 5. Further, the same heating means as the lower mold 52 of the first mold 5 can be applied as the heating means. Therefore, explanation is omitted.

下側保持具62が第一の成形型5の下型52の係合部521に係合し、その状態で、第一の成形型5の上型51と下型52とを接近させると、第一の成形型5の上型51の全部または下側の一部が、第一の成形型5の下型52の係合部521に係合する下側保持具62の壁部622どうしの間に挿抜可能に嵌り込む。そして、下側保持具62の底部621の上側の面と、第一の成形型5の上型51の加圧面512とが、所定の間隔をおいて対向する。   When the lower holder 62 is engaged with the engaging portion 521 of the lower mold 52 of the first mold 5 and the upper mold 51 and the lower mold 52 of the first mold 5 are brought close to each other, All or a part of the lower side of the upper mold 51 of the first mold 5 is formed between the walls 622 of the lower holder 62 that engages with the engaging part 521 of the lower mold 52 of the first mold 5. Fits in and out. The upper surface of the bottom 621 of the lower holding tool 62 and the pressing surface 512 of the upper mold 51 of the first mold 5 are opposed to each other with a predetermined interval.

第一の成形型5の上型51と下型52とが所定の距離に接近した状態における、下側保持具62の溝状の凹部623の内側の面(=底部621の上側の面、または底部621の上側の面と壁部622の互いに対向する面のうちの底部621近傍)と、第一の成形型5の上型51の加圧面512とにより囲まれる空間の形状および寸法が、本ワイヤーハーネス1の所定の部分に形成される形状維持部材12の形状および寸法となる。したがって、下側保持具62の溝状の凹部623の底部621近傍の内側の面の寸法および形状と、第一の成形型5の上型51の加圧面512の寸法および形状は、形状維持部材12の寸法および形状に基づいて設定される。   In the state where the upper mold 51 and the lower mold 52 of the first mold 5 are close to a predetermined distance, the inner surface of the groove-shaped recess 623 of the lower holding tool 62 (= the upper surface of the bottom 621, or The shape and size of the space surrounded by the upper surface of the bottom portion 621 and the vicinity of the bottom portion 621 of the opposing surfaces of the wall portion 622 and the pressing surface 512 of the upper die 51 of the first mold 5 are as follows. It becomes the shape and dimension of the shape maintenance member 12 formed in the predetermined part of the wire harness 1. Accordingly, the size and shape of the inner surface near the bottom 621 of the groove-shaped recess 623 of the lower holding tool 62 and the size and shape of the pressure surface 512 of the upper mold 51 of the first mold 5 are the shape maintaining member. It is set based on 12 dimensions and shapes.

図4〜図8は、それぞれ、第一の工程に含まれる所定の工程を、模式的に示した断面図である。具体的には、図4は、被成形体13により電線11を包む工程を示した図、図5は、電線11および被成形体13を下側保持具62に収容する工程を示した図、図6は、下側保持具62を第一の成形型5の下型52の係合部521に係合する工程を示した図、図7は、第一の成形型5の上型51と下型52とにより被成形体13を加熱および加圧成形している工程を示した図、図8は、電線11および所定の断面形状に成形された形状維持部材12を、第一の成形型5の上型51および下型52から取り外す工程を示した図である。   4 to 8 are cross-sectional views each schematically showing a predetermined process included in the first process. Specifically, FIG. 4 is a diagram illustrating a process of wrapping the electric wire 11 by the molded body 13, and FIG. 5 is a diagram illustrating a process of housing the electric wire 11 and the molded body 13 in the lower holding tool 62. FIG. 6 is a view showing a process of engaging the lower holding tool 62 with the engaging portion 521 of the lower mold 52 of the first mold 5, and FIG. 7 shows the upper mold 51 of the first mold 5. FIG. 8 is a diagram showing a process of heating and press-molding the molded body 13 with the lower mold 52, and FIG. 8 shows the electric wire 11 and the shape maintaining member 12 molded into a predetermined cross-sectional shape as a first mold. It is the figure which showed the process of removing from 5 upper mold | type 51 and lower mold | type 52. FIG.

まず、図4に示すように、被成形体13により電線11の所定の部分を包む。被成形体13には、図4(a)に示すような略平板状の構成のものや、図4(b)に示すように、棒状であって軸線方向に沿ってスリット131(=外周面から内部に達する切り込みまたは溝)が形成される構成のものが適用できる。そして、略平板状の被成形体13が適用される場合には、図4(c)に示すように、被成形体13を略「U」字状に曲げ、電線11の所定の部分を挟み込むようにして包む。一方、棒状の被成形体13が適用される場合には、電線11の所定の部分を被成形体13に形成されるスリット131に挿入することによって、電線11の所定の部分を被成形体13により包む。   First, as shown in FIG. 4, a predetermined portion of the electric wire 11 is wrapped by the molded body 13. The molded body 13 has a substantially flat configuration as shown in FIG. 4A, or a rod-like slit 131 (= outer peripheral surface) as shown in FIG. 4B. A structure in which a notch or a groove reaching from the inside to the inside is formed is applicable. And when the substantially flat molded object 13 is applied, as shown in FIG.4 (c), the molded object 13 is bent in a substantially "U" shape, and the predetermined part of the electric wire 11 is inserted | pinched. Wrap it up. On the other hand, when the rod-shaped molded body 13 is applied, the predetermined portion of the electric wire 11 is inserted into the slit 131 formed in the molded body 13 so that the predetermined portion of the electric wire 11 is inserted into the molded body 13. Wrap with.

被成形体13の断面の形状および寸法は、電線11の所定の部分を包んだ状態において、その断面積(電線11の所定の部分を含めた断面積)が、成形される形状維持部材12の断面積(電線11の所定の部分を含めた断面積)より大きくなればよい。換言すると、成形される形状維持部材12の断面の輪郭線(電線11の所定の部分を含めた断面の輪郭線)が、電線11の所定の部分を包んだ状態における被成形体13の断面の輪郭線の内側に収まるものであればよい。そして、それ以外は特に限定されるものではない。   The shape and dimensions of the cross-section of the molded body 13 are such that the cross-sectional area (the cross-sectional area including the predetermined portion of the electric wire 11) of the shape maintaining member 12 in which the predetermined portion of the electric wire 11 is wrapped is formed. What is necessary is just to become larger than a cross-sectional area (cross-sectional area including the predetermined part of the electric wire 11). In other words, the contour of the cross section of the shape maintaining member 12 to be molded (the contour of the cross section including the predetermined portion of the electric wire 11) What is necessary is just to be inside the outline. Other than that, there is no particular limitation.

次いで、図5に示すように、電線11の所定の部分を包んだ被成形体13を、下側保持具62の溝状の凹部623に収容する。下側保持具62の溝状の凹部623に収容された被成形体13は、両側部622に挟まれることによって、電線11の所定の部分を包んだ状態に維持される。   Next, as shown in FIG. 5, the molded body 13 that encloses a predetermined portion of the electric wire 11 is accommodated in the groove-shaped recess 623 of the lower holding tool 62. The molded body 13 accommodated in the groove-shaped concave portion 623 of the lower holding tool 62 is maintained in a state where a predetermined portion of the electric wire 11 is wrapped by being sandwiched between both side portions 622.

次いで、図6に示すように、電線11の所定の部分を包んだ被成形体13が収容された下側保持具62を、第一の成形型5の下型の係合部521に係合させる。すなわち、下側保持具62を、第一の成形型5の下型52の上側に載置する。   Next, as shown in FIG. 6, the lower holding tool 62 in which the molded body 13 enclosing a predetermined portion of the electric wire 11 is accommodated is engaged with the lower mold engaging portion 521 of the first mold 5. Let That is, the lower holding tool 62 is placed on the upper side of the lower mold 52 of the first mold 5.

第一の成形型5の上型51の加圧面512および第一の成形型5の下型52の係合部521は、加熱手段により所定の温度に維持されている。「所定の温度」は、被成形体13に第一の不織布が適用される場合には、第一の不織布の第二の可塑化温度帯域内の温度が適用される。被成形体13に第二の不織布または発泡体が適用される場合には、第二の不織布の材料または発泡体の材料の融点以上の温度であって、融点近傍の温度が適用される。   The pressure surface 512 of the upper mold 51 of the first mold 5 and the engaging portion 521 of the lower mold 52 of the first mold 5 are maintained at a predetermined temperature by the heating means. The “predetermined temperature” is the temperature within the second plasticization temperature zone of the first nonwoven fabric when the first nonwoven fabric is applied to the molded body 13. When the second nonwoven fabric or foam is applied to the molded body 13, a temperature that is equal to or higher than the melting point of the second nonwoven fabric material or foam material and near the melting point is applied.

次いで、図7に示すように、第一の成形型5の上型51と下型52とを接近させる。そして、第一の成形型5の上型51の加圧面512と下側保持具62の底部の上側の面および側部の内側の面とに囲繞される空間(または、第一の成形型5の上型51の加圧面512と下側保持具62の底部の上側の面とに囲繞される空間)の寸法および形状を、成形後の形状維持部材12の形状および寸法にする。これにより、被成形体13が、第一の成形型5の上型51と、下側保持具62を介して第一の成形型5の下型52とにより、加圧されて圧縮変形するとともに、加熱される。そして、所定の時間にわたって、この状態を維持する(すなわち、被成形体13への加熱および加圧を継続する)。   Next, as shown in FIG. 7, the upper mold 51 and the lower mold 52 of the first mold 5 are brought close to each other. Then, a space (or the first mold 5) surrounded by the pressure surface 512 of the upper mold 51 of the first mold 5 and the upper surface and the inner surface of the bottom of the lower holding tool 62. The dimension and shape of the space surrounded by the pressing surface 512 of the upper mold 51 and the upper surface of the bottom of the lower holding tool 62 are set to the shape and dimensions of the shape maintaining member 12 after molding. As a result, the molded body 13 is compressed and deformed by being pressed by the upper mold 51 of the first mold 5 and the lower mold 52 of the first mold 5 via the lower holder 62. Heated. Then, this state is maintained for a predetermined time (that is, heating and pressurization to the molded body 13 are continued).

「所定の時間」は、次のとおりである。   The “predetermined time” is as follows.

被成形体13に第一の不織布が適用される場合には、被成形体13のうち、下側保持具62の溝状の凹部623の内側の面および第一の成形型5の上型51の加圧面512に接触している部分およびその近傍(換言すると、形状維持部材12の表層部となる部分)は、第二の可塑化温度帯域に達する時間であるが、電線11に接触している部分およびその近傍(換言すると、形状維持部材12の中心部となる部分)は、第二の可塑化温度帯域には達しない時間である。特に、電線11が芯線と芯線を被覆する被覆材とを有する構成である場合には、被覆材が熱により損傷しない時間(換言すると、電線11の被覆材が熱により溶融や変質などしない時間)が適用される。なお、電線11に接触している部分およびその近傍は、第一の可塑化温度帯域に達していてもよく、達していなくてもよい。   When the first nonwoven fabric is applied to the molded body 13, the inner surface of the groove-shaped recess 623 of the lower holding tool 62 and the upper mold 51 of the first mold 5 in the molded body 13. The portion that is in contact with the pressure surface 512 and the vicinity thereof (in other words, the portion that becomes the surface layer portion of the shape maintaining member 12) is the time to reach the second plasticizing temperature zone. The portion and the vicinity thereof (in other words, the portion serving as the central portion of the shape maintaining member 12) are times when the second plasticization temperature zone is not reached. In particular, when the electric wire 11 has a configuration including a core wire and a covering material that covers the core wire, a time during which the covering material is not damaged by heat (in other words, a time during which the covering material of the electric wire 11 is not melted or altered by heat). Applies. Note that the portion in contact with the electric wire 11 and the vicinity thereof may or may not have reached the first plasticization temperature zone.

被成形体13に第二の不織布または発泡体が適用される場合には、被成形体13のうち、下側保持具62の溝状の凹部623の内側の面および第一の成形型5の上型51の加圧面512に接触している部分およびその近傍は、第二の不織布または発泡体の融点以上の温度に達する時間であるが、電線11に接触している部分およびその近傍は、融点に達するよりも短い時間である。特に、電線11が芯線と芯線を被覆する被覆材とを有する構成である場合には、被覆材が熱により損傷しない時間が適用される。   When the second nonwoven fabric or foam is applied to the molded body 13, the inner surface of the groove-shaped recess 623 of the lower holder 62 and the first mold 5 of the molded body 13 are used. The portion in contact with the pressing surface 512 of the upper mold 51 and the vicinity thereof is a time to reach a temperature equal to or higher than the melting point of the second nonwoven fabric or foam, but the portion in contact with the electric wire 11 and the vicinity thereof are The time is shorter than reaching the melting point. In particular, when the electric wire 11 has a configuration including a core wire and a covering material that covers the core wire, a time during which the covering material is not damaged by heat is applied.

被成形体13が、「所定の温度」で「所定の時間」にわたって加熱されながら加圧されると、次のようなプロセスにより、形状維持部材12が形成される。   When the molded body 13 is pressed while being heated at “predetermined temperature” for “predetermined time”, the shape maintaining member 12 is formed by the following process.

被成形体13に第一の不織布が適用される場合には、被成形体13のうちの第一の可塑化温度帯域に達した部分は、熱可塑性により塑性変形する。加熱および加圧されている間においては、被成形体13の表層部(下側保持具62の内側の面に接触している部分およびその近傍と、第一の成形型5の上型51の加圧面512に接触している部分およびその近傍)の温度は、中心部(電線11の所定の部分に接触している部分およびその近傍)に比較して高くなる。このため、被成形体13の表層部の塑性変形の度合は、中心部に比較して大きくなる。したがって、被成形体13の基本繊維およびバインダ繊維の密度は、中心部から表層部に向かうにしたがって高くなる。   When the first nonwoven fabric is applied to the molded body 13, the portion of the molded body 13 that has reached the first plasticization temperature zone is plastically deformed due to thermoplasticity. While being heated and pressurized, the surface layer portion of the molded body 13 (the portion in contact with the inner surface of the lower holding tool 62 and its vicinity, and the upper mold 51 of the first mold 5) The temperature of the portion in contact with the pressing surface 512 and the vicinity thereof is higher than that of the central portion (the portion in contact with the predetermined portion of the electric wire 11 and the vicinity thereof). For this reason, the degree of plastic deformation of the surface layer portion of the molded body 13 is larger than that of the central portion. Therefore, the density of the basic fiber and the binder fiber of the molded body 13 increases from the central portion toward the surface layer portion.

被成形体13の表層部は第二の可塑化温度帯域に達するから、バインダ繊維のバインダ材が溶融し、基本繊維やバインダ繊維どうしを溶着する。このため、被成形体13の表層部は、基本繊維やバインダ繊維の密度が高くなった状態で、バインダ繊維のバインダ材により溶着されるから、中心部に比較して硬くなる。さらに、被成形体13が平板状の構成を有し、曲げられることによって電線11の所定の部分を包んでいる場合には、被成形体13の幅方向の端部の接触している部分どうしが、溶融したバインダ繊維のバインダ材によって溶着する。一方、被成形体13が棒状の構成を有しスリット131の内部に電線11の所定の部分が収容されている場合には、スリット131の内側の面どうしが溶着する。したがって、被成形体13は、電線11の所定の部分の周囲を、切れ目なく覆う構成を有するようになる。   Since the surface layer portion of the molded body 13 reaches the second plasticization temperature zone, the binder material of the binder fiber is melted and the basic fibers and the binder fibers are welded together. For this reason, since the surface layer part of the to-be-molded body 13 is welded by the binder material of a binder fiber in the state where the density of the basic fiber or the binder fiber became high, it becomes hard compared with the center part. Furthermore, when the to-be-molded body 13 has a flat plate-like structure and wraps a predetermined portion of the electric wire 11 by being bent, the portions in contact with the end portions in the width direction of the to-be-molded body 13 are in contact with each other. However, it is welded by the binder material of the melted binder fiber. On the other hand, when the molded body 13 has a rod-like configuration and a predetermined portion of the electric wire 11 is accommodated in the slit 131, the inner surfaces of the slit 131 are welded to each other. Therefore, the to-be-molded body 13 comes to have the structure which covers the circumference | surroundings of the predetermined part of the electric wire 11 without a cut | interruption.

被成形体13に第二の不織布または発泡体が適用される場合には、被成形体13のうち、熱可塑性による塑性変形が可能な温度に達した部分は塑性変形する。加熱および加圧されている間は、被成形体13の表層部の温度は、中心部に比較して高くなるから、被成形体13の表層部の塑性変形の度合は、中心部に比較して大きくなる。したがって、被成形体13の密度は、中心部から表層部に向かうにしたがって高くなる。   When the second non-woven fabric or foam is applied to the molded body 13, a portion of the molded body 13 that has reached a temperature at which plastic deformation due to thermoplasticity can be plastically deformed. While being heated and pressurized, the temperature of the surface layer portion of the molded body 13 is higher than that of the central portion, and therefore the degree of plastic deformation of the surface layer portion of the molded body 13 is higher than that of the central portion. Become bigger. Therefore, the density of the molded body 13 increases as it goes from the center to the surface layer.

さらに、被成形体13の表層部は融点以上の温度に達するから、被成形体13の表層部が溶融する。このため、被成形体13に第二の不織布が適用される場合には、溶融した繊維どうしが結合して一体化し、繊維の構造が消失する。一方、被成形体13に発泡体が適用される場合には、溶融して気泡が抜ける。このため、被成形体13の表層部は、繊維の状態または発泡体の状態に比較して、密度が高くなるとともに硬度が上昇する。さらに、被成形体13が平板状の構成を有し、曲げられることによって電線11の所定の部分を包んでいる場合には、被成形体13の幅方向の端部どうしが、溶融して溶着する。一方、被成形体13が棒状の構成を有しスリット131の内部に電線11の所定の部分が収容されている場合には、スリット131の内側の面どうしが溶融して溶着する。したがって、被成形体13は、電線11の所定の部分の周囲を、切れ目なく覆う構成を有するようになる。   Furthermore, since the surface layer portion of the molded body 13 reaches a temperature equal to or higher than the melting point, the surface layer portion of the molded body 13 is melted. For this reason, when a 2nd nonwoven fabric is applied to the to-be-molded body 13, the melted fibers couple | bond together and are integrated and the structure of a fiber lose | disappears. On the other hand, when a foam is applied to the molded body 13, it melts and bubbles are removed. For this reason, as for the surface layer part of the to-be-molded body 13, compared with the state of a fiber or the state of a foam, a density becomes high and hardness rises. Further, when the molded body 13 has a flat configuration and wraps a predetermined portion of the electric wire 11 by being bent, the ends in the width direction of the molded body 13 are melted and welded. To do. On the other hand, when the molded body 13 has a rod-like configuration and a predetermined portion of the electric wire 11 is accommodated in the slit 131, the inner surfaces of the slit 131 are melted and welded. Therefore, the to-be-molded body 13 comes to have the structure which covers the circumference | surroundings of the predetermined part of the electric wire 11 without a cut | interruption.

なお、第一の成形型5の下型52が発する熱は、下側保持具62を通じて被成形体13に伝わる。前記のとおり、下側保持具62は熱伝導率の高い材料から形成され、かつ外側の面から内側の面に向かって熱を伝えやすい構成であるから、第一の成形型5の下型52が発する熱は、被成形体13に伝わりやすい。このため、前記「所定の時間」を長くする必要がない。   The heat generated by the lower mold 52 of the first mold 5 is transmitted to the molded body 13 through the lower holder 62. As described above, the lower holding tool 62 is formed of a material having high thermal conductivity and has a structure that easily transfers heat from the outer surface to the inner surface, and therefore, the lower mold 52 of the first mold 5. The heat generated is easily transmitted to the molded body 13. For this reason, it is not necessary to lengthen the “predetermined time”.

次いで、図8に示すように、所定の時間経過後、第一の成形型5の上型51と下型52とが分離される。そして、本ワイヤーハーネス1の所定の部分(すなわち、成形された形状維持部材12と、電線11の所定の部分)が、下側保持具62に載置された状態で、下型から取り外される。   Next, as shown in FIG. 8, after a predetermined time has elapsed, the upper mold 51 and the lower mold 52 of the first mold 5 are separated. And the predetermined part (namely, the shape maintenance member 12 shape | molded and the predetermined part of the electric wire 11) of this wire harness 1 is removed from a lower mold | type in the state mounted in the lower holder 62. FIG.

下側保持具62が、金属板などからなる構成であれば(すなわち、質量が小さい構成であれば)、蓄熱量が小さいから、本ワイヤーハーネス1の所定の部分が第一の成形型5の下型52から取り外された後は、成形された形状維持部材12および電線11の所定の部分は、下側保持具62が有する熱によって加熱されることがない。このため、本ワイヤーハーネス1の所定の部分が必要以上に加熱されることを防止できる。したがって、形状維持部材12の性質の制御が容易となる。さらに、下側保持具62の溝状の凹部623に収容された状態で、第一の成形型5の下型52から取り外されるから、成形された形状維持部材12が自重などによって変形することが防止できる。また、取り外す際に、形状維持部材12に直接的に接触する必要がないから、形状維持部材12に不測の変形や望まない変形が生じることがない。   If the lower holder 62 is made of a metal plate or the like (that is, if the mass is small), the heat storage amount is small, so that the predetermined part of the wire harness 1 is the first mold 5. After being removed from the lower mold 52, the molded shape maintaining member 12 and the predetermined portions of the electric wire 11 are not heated by the heat of the lower holder 62. For this reason, it can prevent that the predetermined part of this wire harness 1 is heated more than necessary. Accordingly, it becomes easy to control the properties of the shape maintaining member 12. Furthermore, since it is removed from the lower mold 52 of the first mold 5 while being accommodated in the groove-shaped recess 623 of the lower holding tool 62, the molded shape maintaining member 12 may be deformed by its own weight or the like. Can be prevented. Moreover, since it is not necessary to contact the shape maintenance member 12 directly when removing, an unexpected deformation | transformation and an undesired deformation | transformation do not arise in the shape maintenance member 12. FIG.

このように、被成形体13を加熱および加圧することにより、所定の断面形状の形状維持部材12を成形することができる。成形された形状維持部材12の表層部は、成形前の被成形体13に比較して、密度が高くかつ硬さが高くなっている。一方、形状維持部材12の中心部は、成形前の被成形体13の物理的性質を有しており、電線の所定の部分に弾性的に接触している。   Thus, the shape maintaining member 12 having a predetermined cross-sectional shape can be formed by heating and pressurizing the molded body 13. The surface layer portion of the molded shape maintaining member 12 has a higher density and a higher hardness than the molded body 13 before molding. On the other hand, the central portion of the shape maintaining member 12 has physical properties of the molded body 13 before molding, and is in elastic contact with a predetermined portion of the electric wire.

図9は、第一の工程を経た本ワイヤーハーネス1の所定の部分を抜き出して示した外観斜視図である。図9に示すように、第一の工程を経ると、本ワイヤーハーネス1の電線11の所定の部分に、所定の断面形状および寸法を有する形状維持部材12が設けられる。形状維持部材12の軸線の形状は、下側保持具62の軸線の形状と略等しくなる。たとえば、図9に示すように、略直線に形成される。すなわち、第一の工程を経た直後においては、形状維持部材12は、最終的に成形すべき軸線形状を有していない。   FIG. 9 is an external perspective view showing a predetermined portion of the wire harness 1 that has undergone the first step. As shown in FIG. 9, after the first step, a shape maintaining member 12 having a predetermined cross-sectional shape and dimensions is provided in a predetermined portion of the electric wire 11 of the wire harness 1. The shape of the axis of the shape maintaining member 12 is substantially equal to the shape of the axis of the lower holder 62. For example, as shown in FIG. 9, it is formed in a substantially straight line. That is, immediately after the first step, the shape maintaining member 12 does not have an axial shape to be finally formed.

第一の工程を経た本ワイヤーハーネス1の所定の部分は、第二の工程に移される。第二の工程の内容は、次のとおりである。第二の工程においては、形状維持部材12の軸線形状を所定の形状に成形するための成形型7が使用される。この成形型7を、第二の成形型7と称する。図10は、第二の成形型7の構成を、模式的に示した分解斜視図である。図10に示すように、第二の成形型7は、上型71と下型72とを有する。   The predetermined part of the wire harness 1 that has undergone the first step is moved to the second step. The contents of the second step are as follows. In the second step, a molding die 7 for molding the shape of the shape maintaining member 12 into a predetermined shape is used. This mold 7 is referred to as a second mold 7. FIG. 10 is an exploded perspective view schematically showing the configuration of the second mold 7. As shown in FIG. 10, the second mold 7 has an upper mold 71 and a lower mold 72.

図10に示すように、第二の成形型7の下型72には、成形部721が形成される。成形部721は、形状維持部材12を挿入可能な溝であり、その軸線の形状は、最終的に形成される形状維持部材12の軸線の形状に応じて設定される。すなわち、成形部721の軸線の形状および寸法が、最終的に製造される本ワイヤーハーネス1の形状維持部材12の軸線の形状および寸法となる。したがって、成形部721の軸線の形状および寸法は、製造したい形状維持部材12の形状および寸法に応じて設定される。図10に示す成形部721の形状は、一例であり、この形状に限定されるものではない。   As shown in FIG. 10, a molding part 721 is formed on the lower mold 72 of the second mold 7. The forming part 721 is a groove into which the shape maintaining member 12 can be inserted, and the shape of the axis thereof is set according to the shape of the axis of the shape maintaining member 12 to be finally formed. That is, the shape and size of the axis of the forming part 721 become the shape and size of the axis of the shape maintaining member 12 of the wire harness 1 that is finally manufactured. Therefore, the shape and size of the axis of the forming portion 721 are set according to the shape and size of the shape maintaining member 12 to be manufactured. The shape of the forming portion 721 shown in FIG. 10 is an example, and is not limited to this shape.

第二の成形型7の上型71は、下型72に結合可能な構成を有する。そして、第二の成形型7の上型71と下型72とが結合した状態において、下型72の成形部721の内側の面と、上型71の表面のうちの下型72の成形部721を臨む部分とに囲まれる空間の寸法および形状が、本ワイヤーハーネス1の所定の部分に設けられる形状維持部材12の最終的な寸法および形状となる。   The upper mold 71 of the second mold 7 has a configuration that can be coupled to the lower mold 72. Then, in a state where the upper mold 71 and the lower mold 72 of the second mold 7 are coupled, the inner surface of the molded section 721 of the lower mold 72 and the molded section of the lower mold 72 out of the surface of the upper mold 71. The size and shape of the space surrounded by the portion facing 721 is the final size and shape of the shape maintaining member 12 provided in a predetermined portion of the wire harness 1.

第二の成形型7の上型71および下型72の材質は、特に限定されるものではないが、熱伝導率が高い材料が適用されることが好ましい。たとえば、鉄系の金属材料やアルミ合金などの各種金属材料が適用できる。   Although the material of the upper mold | type 71 and the lower mold | type 72 of the 2nd shaping | molding die 7 is not specifically limited, It is preferable that the material with high heat conductivity is applied. For example, various metal materials such as iron-based metal materials and aluminum alloys can be applied.

第一の工程を経た本ワイヤーハーネス1の所定の部分(=成形された形状維持部材12)が、熱可塑性による塑性変形が可能な温度にあるうちに、第二の成形型7の下型72の成形部721に嵌め込まれ、上型71と下型72とが結合される。すなわち、形状維持部材12に第一の不織布が適用される場合には、形状維持部材12が第一の可塑化温度帯域にあるうちに、第二の成形型7の下型72の成形部721に嵌め込まれ、上型71と下型72とが結合される。   While the predetermined part (= the molded shape maintaining member 12) of the wire harness 1 that has undergone the first step is at a temperature at which plastic deformation by thermoplasticity is possible, the lower mold 72 of the second mold 7 The upper die 71 and the lower die 72 are coupled to each other. That is, when the first nonwoven fabric is applied to the shape maintaining member 12, the molding portion 721 of the lower mold 72 of the second molding die 7 while the shape maintaining member 12 is in the first plasticizing temperature zone. And the upper die 71 and the lower die 72 are combined.

形状維持部材12が第二の成形型7の下型72の成形部721に嵌め込まれると、形状維持部材12は、成形部721の形状に倣った形状に塑性変形する。特に、形状維持部材12の軸線の形状が、成形部721の軸線の形状と同じ形状に塑性変形する。   When the shape maintaining member 12 is fitted into the forming portion 721 of the lower mold 72 of the second forming die 7, the shape maintaining member 12 is plastically deformed into a shape following the shape of the forming portion 721. In particular, the shape of the axis of the shape maintaining member 12 is plastically deformed to the same shape as the shape of the axis of the forming portion 721.

そして、形状維持部材12が、熱可塑性による塑性変形を生じない温度に低下するまで、この状態が維持される。たとえば、形状維持部材12に第一の不織布が適用される場合には、形状維持部材12が第一の不織布の第一の可塑化温度帯域よりも低い温度に下がるまで、この状態が維持される。   And this state is maintained until the shape maintenance member 12 falls to a temperature at which plastic deformation due to thermoplasticity does not occur. For example, when a 1st nonwoven fabric is applied to the shape maintenance member 12, this state is maintained until the shape maintenance member 12 falls to temperature lower than the 1st plasticization temperature zone of a 1st nonwoven fabric. .

成形された形状維持部材12が、第二の成形型7の下型72の成形部721に嵌め込まれ、上型71と下型72とが結合されると、形状維持部材12の表面が、第二の成形型7の下型72の成形部721の内面と上型71の表面に接触する。そして、形状維持部材12が有する熱は、第二の成形型7の上型71および下型72に伝導し、さらに第二の成形型7の上型71および下型72から外部(たとえば大気中)に放散される。前記のとおり、第二の成形型7の上型71および下型72が、熱伝導率の高い材料により形成されるものであれば、成形部721に嵌め込まれた形状維持部材12が有する熱は、速やかに第二の成形型7の上型71および下型72に伝導され、形状維持部材12が急速に冷却される。   When the molded shape maintaining member 12 is fitted into the molded portion 721 of the lower mold 72 of the second mold 7 and the upper mold 71 and the lower mold 72 are coupled, the surface of the shape maintaining member 12 is The inner surface of the molding part 721 of the lower mold 72 of the second molding die 7 and the surface of the upper mold 71 are brought into contact with each other. Then, the heat of the shape maintaining member 12 is conducted to the upper mold 71 and the lower mold 72 of the second mold 7 and further from the upper mold 71 and the lower mold 72 of the second mold 7 to the outside (for example, in the atmosphere). ). As described above, if the upper mold 71 and the lower mold 72 of the second mold 7 are formed of a material having high thermal conductivity, the heat of the shape maintaining member 12 fitted in the molded portion 721 is The shape maintaining member 12 is rapidly cooled by being quickly conducted to the upper mold 71 and the lower mold 72 of the second mold 7.

形状維持部材12の温度が、熱可塑性による塑性変形が生じない温度以下に下がった後に、第二の成形型7の上型71と下型72とが分離され、形状維持部材12が第二の成形型7の下型72の成形部721から取り外される。以上の工程を経て、所定の形状および寸法に形成された形状維持部材12を有する本ワイヤーハーネス1が得られる。   After the temperature of the shape maintaining member 12 falls below a temperature at which plastic deformation due to thermoplasticity does not occur, the upper mold 71 and the lower mold 72 of the second mold 7 are separated, and the shape maintaining member 12 is The mold 7 is removed from the molding portion 721 of the lower mold 72. Through this process, the wire harness 1 having the shape maintaining member 12 formed in a predetermined shape and size is obtained.

なお、第二の成形型7は、上型71を有さない構成であってもよい。すなわち、第二の成形型7の下型71のみであっても、形状維持部材12を充分に冷却できる場合や、上型71により形状維持部材12を押さえる必要がない場合(たとえば、上型72により形状維持部材12を押さえなくとも、形状維持部材12が元の形状に戻るおそれがない場合)には、上型72を備えなくともよい。   The second mold 7 may be configured without the upper mold 71. That is, even when only the lower mold 71 of the second mold 7 is used, the shape maintaining member 12 can be sufficiently cooled, or the shape maintaining member 12 does not need to be pressed by the upper mold 71 (for example, the upper mold 72 If the shape maintaining member 12 is not likely to return to its original shape without pressing the shape maintaining member 12, the upper die 72 may not be provided.

さらに、第二の成形型7は、形状維持部材12の軸線を所定の形状に成形できる構造物であればよく、専用の成形型を用いる必要はない。たとえば、本ワイヤーハーネス1を配索する領域が設けられる実物の部材を、第二の成形型7として用いてもよい。   Furthermore, the second mold 7 may be a structure that can mold the axis of the shape maintaining member 12 into a predetermined shape, and it is not necessary to use a dedicated mold. For example, a real member provided with a region in which the wire harness 1 is routed may be used as the second mold 7.

たとえば、自動車のピラー(前面窓もしくは後部窓と側面窓の間にある支柱、または側面窓どうしの間にある支柱)に配索される部分を有するワイヤーハーネスを製造する場合には、実物のピラーを、第二の成形型7として用いることができる。そして、第一の工程を経て成形された形状維持部材12(=本ワイヤーハーネス1の所定の部分)を、実際に配索する態様でピラーに載置する。そして、形状維持部材12が熱可塑性による塑性変形が生じない温度に低下するまで、その状態を維持する。これにより、形状維持部材12(特に、形状維持部材12の軸線形状)を、実際に配索される空間の形状に成形することができる。   For example, when manufacturing a wire harness having a part routed on a pillar of an automobile (a pillar between a front window or a rear window and a side window, or a pillar between side windows), the actual pillar Can be used as the second mold 7. And the shape maintenance member 12 (= predetermined part of this wire harness 1) shape | molded through the 1st process is mounted in a pillar in the aspect actually routed. The state is maintained until the shape maintaining member 12 is lowered to a temperature at which plastic deformation due to thermoplasticity does not occur. Thereby, the shape maintenance member 12 (especially the axial shape of the shape maintenance member 12) can be shape | molded in the shape of the space actually routed.

また、自動車のドアに配索される部分を有するワイヤーハーネスを製造する場合には、実物のドアとなる部材(ドアの外板および外板に溶接などされるフレーム)を、第二の成形型7として用いることができる。そして、前記同様の工程を経て、形状維持部材12を、実際に配索される空間の形状に成形することができる。   In addition, when manufacturing a wire harness having a portion that is routed to the door of an automobile, a member that becomes a real door (a frame that is welded to the outer plate of the door and the outer plate) is used as the second mold. 7 can be used. And the shape maintenance member 12 can be shape | molded in the shape of the space actually routed through the same process as the above.

このように、本ワイヤーハーネス1の所定の部分が配索される実物の部材を、第二の成形型7として用いることができる。このような構成によれば、専用の第二の成形型7を製造する必要がないから、第二の成形型の設計や製造に要する労力やコストを削減できるから、設備コストの削減を図ることができる。また、実際に配索される実物の部材を用いるから、形状維持部材12を、正確かつ精度良く、所定の形状に成形することができる。   Thus, the actual member in which the predetermined part of the wire harness 1 is routed can be used as the second mold 7. According to such a configuration, since it is not necessary to manufacture the dedicated second mold 7, the labor and cost required for designing and manufacturing the second mold can be reduced, so that the equipment cost can be reduced. Can do. Moreover, since the actual member actually routed is used, the shape maintaining member 12 can be accurately and accurately formed into a predetermined shape.

本発明の実施形態にかかるワイヤーハーネスの製造方法によれば、第一の成形型5を用いて被成形体13を加熱および加圧して、所定の断面形状および寸法を有する形状維持部材12を成形することができる。すなわち、電線11の所定の部分を覆うように形状維持部材12を成形することができる。そして、第二の成形型7を用いることにより、形状維持部材12を所定の軸線形状に成形するとともに、冷却することができる。   According to the method for manufacturing a wire harness according to the embodiment of the present invention, the shape maintaining member 12 having a predetermined cross-sectional shape and dimensions is formed by heating and pressurizing the molded body 13 using the first mold 5. can do. That is, the shape maintaining member 12 can be formed so as to cover a predetermined portion of the electric wire 11. Then, by using the second mold 7, the shape maintaining member 12 can be molded into a predetermined axial shape and cooled.

このため、形状維持部材12の軸線形状が複雑な形状(たとえば、複雑な三次元形状)であっても、容易かつ安価に成形することができる。すなわち、射出成形品を用いる構成では、形状維持部材の軸線形状が複雑な形状となると、射出成形型の設計が複雑となり、設備コストの上昇を招く。これに対して、本発明の実施形態にかかるワイヤーハーネスの製造方法によれば、形状維持部材12を、たとえば配索される空間の形状に応じた形状に容易かつ安価に成形することができる。   For this reason, even if the axial shape of the shape maintaining member 12 is a complicated shape (for example, a complicated three-dimensional shape), it can be easily and inexpensively formed. That is, in the configuration using the injection molded product, when the axial shape of the shape maintaining member becomes a complicated shape, the design of the injection mold becomes complicated, resulting in an increase in equipment cost. On the other hand, according to the manufacturing method of the wire harness concerning embodiment of this invention, the shape maintenance member 12 can be shape | molded easily and cheaply, for example in the shape according to the shape of the routed space.

また、電線の軸線形状を所定の形状に維持するためにテープを巻き付ける構成と比較すると、作業内容が大幅に単純化されるから、製造に要する手間や時間を省略することができる。さらに、手作業でテープを巻き付ける構成と比較すると、品質の安定化を図ることができる。そして、本発明の実施形態にかかるワイヤーハーネスの製造方法によれば、製造されるワイヤーハーネスの見映えがよい。   Moreover, compared with the structure which winds a tape in order to maintain the axial shape of an electric wire in a predetermined | prescribed shape, since the work content is simplified greatly, the effort and time which manufacture requires can be omitted. Furthermore, quality can be stabilized as compared with a configuration in which a tape is wound manually. And according to the manufacturing method of the wire harness concerning embodiment of this invention, the appearance of the manufactured wire harness is good.

形状維持部材12は、第二の成形型7を用いることにより、所定の軸線形状に成形されるとともに、熱可塑性による塑性変形が生じない温度にまで冷却される。したがって、形状維持部材12は、第二の成形型から取り外された時点において、形状が確定しており、熱可塑性による塑性変形が生じない。したがって、成形された形状維持部材12に、不測の変形や、望まない変形が生じることなく、寸法精度のよい形状維持部材を成形することができる。さらに、成形された形状維持部材12の取り扱いが容易となる。   By using the second mold 7, the shape maintaining member 12 is molded into a predetermined axial shape and cooled to a temperature at which plastic deformation due to thermoplasticity does not occur. Therefore, when the shape maintaining member 12 is removed from the second mold, the shape is fixed, and plastic deformation due to thermoplasticity does not occur. Therefore, it is possible to form a shape maintaining member with good dimensional accuracy without causing unexpected deformation or undesired deformation on the formed shape maintaining member 12. Furthermore, handling of the molded shape maintaining member 12 becomes easy.

すなわち、一基の成形型を用い、被成形体の断面を所定の形状および寸法に形成すると同時に、形状維持部材の軸線を所定の形状に成形する構成であると、成形直後の形状維持部材の温度は、熱可塑性による塑性変形が可能な温度であるから、成形後に、不測の変形や望まない変形が生じることがある。これに対して本発明の実施形態にかかるワイヤーハーネスの製造方法によれば、形状維持部材12の温度は、第二の成形型7から取り出された時点において、既に熱可塑性による塑性変形が生じない温度にある。このため、成形された形状維持部材12に触れても、不測の変形などが生じることがない。   That is, using a single mold, the cross section of the object to be molded is formed into a predetermined shape and dimensions, and at the same time, the shape maintaining member has an axis formed into a predetermined shape. Since the temperature is a temperature at which plastic deformation by thermoplasticity is possible, unexpected deformation or undesired deformation may occur after molding. On the other hand, according to the method for manufacturing the wire harness according to the embodiment of the present invention, the temperature of the shape maintaining member 12 does not already cause plastic deformation due to thermoplasticity when it is taken out from the second mold 7. In temperature. For this reason, even if the molded shape maintaining member 12 is touched, unexpected deformation or the like does not occur.

なお、一基の成形型を用いて形状維持部材を成形する構成においては、形状維持部材を成形後、成形型を冷却してから形状維持部材を取り外す構成が考えられる。しかしながらこのような構成では、成形型を冷却するための時間を要するため、形状維持部材の成形に要する時間が長くなり、製造効率が低下する。さらに、成形型が冷却するまでの間は、成形型によって形状維持部材が加熱され続けるから、形状維持部材の性質の調整が困難となる。さらに、形状維持部材を成形するごとに、成形型の加熱と冷却が必要となるから、形状維持部材の成形に要する時間が長くなる。   In addition, in the structure which shape | molds a shape maintenance member using one shaping | molding die, after forming a shape maintenance member, the structure which removes a shape maintenance member after cooling a shaping | molding die can be considered. However, in such a configuration, since it takes time to cool the mold, the time required for forming the shape maintaining member becomes long, and the manufacturing efficiency is lowered. Furthermore, since the shape maintaining member is continuously heated by the mold until the mold is cooled, it is difficult to adjust the properties of the shape maintaining member. Furthermore, each time the shape maintaining member is molded, the mold needs to be heated and cooled, so that the time required for forming the shape maintaining member becomes longer.

これに対して本発明の実施形態にかかるワイヤーハーネスの製造方法によれば、第一の成形型5を冷却する必要がなく、常に所定の温度に維持できる。このため、第一の成形型5の稼働効率の向上を図ることができる。また、成形型を冷却する構成と比較すると、成形型の冷却のために必要な時間と、形状維持部材の冷却のために必要な時間とでは、形状維持部材を冷却するために必要な時間の方が短くできるから(すなわち、成形型の蓄熱量と、成形された形状維持部材の蓄熱量とでは、成形された形状維持部材の蓄熱量の方が少ない)、形状維持部材の成形(特に冷却)に要する時間を短くできる。   On the other hand, according to the manufacturing method of the wire harness concerning embodiment of this invention, it is not necessary to cool the 1st shaping | molding die 5, and it can always maintain at predetermined temperature. For this reason, the operating efficiency of the first mold 5 can be improved. In addition, when compared with the configuration in which the mold is cooled, the time required for cooling the mold and the time required for cooling the shape maintaining member are equal to the time required for cooling the shape maintaining member. The shape can be shortened (that is, the heat storage amount of the molding die and the heat storage amount of the molded shape maintaining member is smaller than that of the molded shape maintaining member). ) Can be shortened.

被成形体13を加熱する手段は、第一の成形型5にのみ設けけられる構成であればよく、第二の成形型7に設ける必要はない。また、第二の成形型7は、形状維持部材12を所定の軸線形状に成形することができる構成を有していればよいから、専用の成形型を用いる必要はなく、本ワイヤーハーネス1の所定の部分が配索される実物の部材を、そのまま適用できる。したがって、第二の成形型7の製造コストの削減を図ることができ、本発明の実施形態にかかるワイヤーハーネスの製造方法において使用する設備コストの削減を図ること、または設備コストの上昇を防止することができる。   The means for heating the body 13 need only be configured to be provided only in the first mold 5, and need not be provided in the second mold 7. Moreover, since the 2nd shaping | molding die 7 should just have the structure which can shape | mold the shape maintenance member 12 in a predetermined | prescribed axial line shape, it is not necessary to use an exclusive shaping | molding die, A real member in which a predetermined portion is routed can be applied as it is. Therefore, the manufacturing cost of the second mold 7 can be reduced, and the equipment cost used in the method of manufacturing the wire harness according to the embodiment of the present invention can be reduced or the equipment cost can be prevented from rising. be able to.

さらに、形状維持部材12は、第二の成形型7(加熱手段を有さない成形型)により所定の軸線形状に成形されるため、第一の成形型5(加熱手段を有する成形型)および下側保持具62の形状を単純な形状にすることができる。たとえば、下側保持具62を略直線の棒状に形成し、第一の成形型5の下型52の係合部521と、上型51の加圧面512を略直線に形成することができる。このように、加熱手段を有する第一の成形型5の形状を、単純な形状とすることができる。したがって、第一の成形型5の製造コストの削減を図ることができる。すなわち、一基の成形型により被成形体を所定の断面形状および寸法に形成するとともに、所定の軸線形状に成形する構成と比較すると、被成形体13を加熱する成形型の形状が簡単になるから、成形型の製造コストの削減を図ることができる。   Furthermore, since the shape maintaining member 12 is molded into a predetermined axial shape by the second molding die 7 (molding die not having heating means), the first molding die 5 (molding die having heating means) and The shape of the lower holder 62 can be a simple shape. For example, the lower holding tool 62 can be formed in a substantially straight rod shape, and the engaging portion 521 of the lower mold 52 of the first mold 5 and the pressing surface 512 of the upper mold 51 can be formed in a substantially straight line. Thus, the shape of the 1st shaping | molding die 5 which has a heating means can be made into a simple shape. Therefore, the manufacturing cost of the first mold 5 can be reduced. That is, while forming a to-be-formed body into a predetermined cross-sectional shape and size with a single forming die, the shape of the forming die for heating the to-be-formed body 13 is simplified as compared with a configuration in which it is formed into a predetermined axial shape. Therefore, the manufacturing cost of the mold can be reduced.

そして、本発明の実施形態にかかるワイヤーハーネスの製造方法によれば、形状維持部材12の表層部を硬化させ、中心部を軟らかい状態(成形前における被成形体13の物理的性質を有する状態)に維持することが容易となる。   And according to the manufacturing method of the wire harness concerning embodiment of this invention, the surface layer part of the shape maintenance member 12 is hardened, and a center part is a soft state (state which has the physical property of the to-be-molded body 13 before shaping | molding). It becomes easy to maintain.

すなわち、第一の成形型5により加熱および加圧が完了した後(=第一の工程を経た後)、形状維持部材12を直ちに第二の成形型7の下型72の成形部721に嵌め込むことにより、速やかに冷却を開始することができる。第一の成形型5により加熱および加圧された直後の形状維持部材12の温度は、表層部が高く中心部が低い。このため、この状態で放置されると、表層部の熱が中心部に伝わり、中心部においても熱可塑性による塑性変形が進行して硬くなるおそれがある。これに対して、本発明の実施形態にかかるワイヤーハーネスの製造方法によれば、成形された形状維持部材12が有する熱(特に、表層部が有する熱)は、速やかに第二の成形型7に伝導される。したがって、中心部における塑性変形の進行を防止することができる。   That is, after heating and pressurization are completed by the first mold 5 (= after the first step), the shape maintaining member 12 is immediately fitted into the molding part 721 of the lower mold 72 of the second mold 7. The cooling can be started promptly. The temperature of the shape maintaining member 12 immediately after being heated and pressurized by the first mold 5 is high in the surface layer portion and low in the central portion. For this reason, if it is left in this state, the heat of the surface layer portion is transmitted to the central portion, and plastic deformation due to thermoplasticity may progress in the central portion and become hard. On the other hand, according to the method for manufacturing the wire harness according to the embodiment of the present invention, the heat of the molded shape maintaining member 12 (particularly, the heat of the surface layer portion) is quickly supplied to the second mold 7. Conducted by Therefore, the progress of plastic deformation in the central portion can be prevented.

さらに、下側保持具62を用いる構成であると、第一の成形型5による加圧成形前において、被成形体13が不要に加熱されることを防止できる。すなわち、第一の成形型5に直接に被成形体13および電線11の所定の部分をセッティングする構成では、このセッティングの作業において時間がかかると、加圧する前に被成形体13が加熱される。このため、被成形体13のうちの形状維持部材12の中心部となる部分が、熱可塑性による塑性変形可能な温度に達する場合や、融点に達する場合がある。そうすると、形状維持部材12の表層部のみならず中心部も硬化するおそれがある。さらに、電線11が熱により損傷するおそれもある。これに対して、下側保持具62を用いる構成によれば、被成形体13と電線11の所定の部分を下側保持具62に収容する作業においては、被成形体13が加熱されることがない。そして、下側保持具62に収容された被成形体13を第一の成形型5の下型52に係合部521に係合させた後は、直ちに加圧を行うことができる。したがって、被成形体13の表層部を所定の温度に達するように加熱するとともに、中心部は所定の温度に達しないようにすることができる。   Furthermore, with the configuration using the lower holding tool 62, it is possible to prevent the molded body 13 from being unnecessarily heated before the pressure molding by the first molding die 5. That is, in the configuration in which the molding target 13 and the predetermined portion of the electric wire 11 are set directly on the first mold 5, if the setting operation takes time, the molding target 13 is heated before pressurization. . For this reason, the part used as the center part of the shape maintenance member 12 of the to-be-molded body 13 may reach the temperature which can be plastically deformed by thermoplasticity, or may reach melting | fusing point. If it does so, there exists a possibility that not only the surface layer part of the shape maintenance member 12 but a center part may also harden | cure. Further, the electric wire 11 may be damaged by heat. On the other hand, according to the configuration using the lower holding tool 62, the molding target 13 is heated in the operation of accommodating the molding target 13 and the predetermined portion of the electric wire 11 in the lower holding tool 62. There is no. And after making the to-be-molded body 13 accommodated in the lower holding tool 62 engage the engaging part 521 with the lower mold 52 of the first mold 5, pressurization can be performed immediately. Accordingly, the surface layer portion of the molded body 13 can be heated so as to reach a predetermined temperature, and the central portion can be prevented from reaching the predetermined temperature.

このように、形状維持部材12の表層部を硬化させ、中心部を硬化させないようにすることが容易となる。さらに、電線11が熱損傷しないようにできる。   Thus, it becomes easy to cure the surface layer portion of the shape maintaining member 12 and not cure the center portion. Furthermore, the electric wire 11 can be prevented from being damaged by heat.

そして、本発明の実施形態にかかるワイヤーハーネスの製造方法によれば、大量生産において、時間あたりの製造数を増加させることができる。たとえば、ある一つの被成形体13を第一の成形型5により加熱するとともに加圧し、その後、当該ある一つの被成形体13により成形された形状維持部材12を、第二の成形型7により所定の軸線形状に成形するとともに冷却している間に、他の一つの被成形体13を、第一の成形型5により加熱するとともに加圧することができる。そして、このような工程を、繰り返して行うことができる。このように、第一の成形型5および第二の成形型7を用いることにより、休みなく形状維持部材12の成形を行うことができる。   And according to the manufacturing method of the wire harness concerning embodiment of this invention, the number of manufacture per time can be increased in mass production. For example, a certain molded object 13 is heated and pressurized by the first mold 5, and then the shape maintaining member 12 molded by the one molded object 13 is transferred by the second mold 7. While being molded into a predetermined axial shape and being cooled, the other one molded object 13 can be heated and pressurized by the first mold 5. And such a process can be performed repeatedly. Thus, by using the first mold 5 and the second mold 7, the shape maintaining member 12 can be molded without a break.

このほか、本発明の実施形態にかかるワイヤーハーネスの製造方法によれば、射出成形品の形状維持部材を用いる構成と比較すると、次のような作用効果を奏することができる。   In addition, according to the manufacturing method of the wire harness concerning embodiment of this invention, compared with the structure which uses the shape maintenance member of an injection molded product, there can exist the following effects.

本発明の実施形態にかかるワイヤーハーネスの製造方法において使用される第一の成形型5および第二の成形型7は、射出成形品を製造する金型(いわゆる射出成形用の金型)に比較して、構造が簡単であるから、安価に製造でき、設備コストの削減を図ることができる。また、本発明の実施形態にかかるワイヤーハーネスの製造方法によれば、射出成形品の形状維持部材やプロテクタを用いる構成と比較して、形状維持部材12に安価な材料(市販の安価な熱可塑性材料)が適用できるから、本ワイヤーハーネスを安価に製造することができる。このため、製品の低価格化を図ることができる。   The first mold 5 and the second mold 7 used in the method for manufacturing a wire harness according to the embodiment of the present invention are compared with a mold for manufacturing an injection molded product (so-called injection mold). Since the structure is simple, it can be manufactured at low cost and the equipment cost can be reduced. Moreover, according to the manufacturing method of the wire harness concerning embodiment of this invention, compared with the structure which uses the shape maintenance member and protector of an injection molded product, it is cheap material (commercially inexpensive thermoplasticity) for the shape maintenance member 12. This material can be applied at low cost. For this reason, it is possible to reduce the price of the product.

そして、本発明の実施形態にかかるワイヤーハーネスの製造方法における第一の工程および第二の工程は、射出成形品のプロテクタや形状維持部材に電線を嵌め込む方法に比較して、作業が簡単である。   And the 1st process and the 2nd process in the manufacturing method of the wire harness concerning the embodiment of the present invention are simple work compared with the method of fitting an electric wire in the protector and shape maintenance member of an injection-molded product. is there.

また、射出成形品のプロテクタや形状維持部材を用いる構成においては、プロテクタや形状維持部材の内面と電線との間に隙間があると、振動などによって電線がプロテクタや形状維持部材の内面と衝突し、衝突音などが発生する。なお、射出成形品のプロテクタや形状維持部材の内部にスポンジなどの緩衝材を挿入して衝突音などを防止する構成があるが、このような構成とすると、部品点数や作業工数が増加し、製造コストや製品価格の上昇を招くおそれがある。   In addition, in a configuration using a protector or shape maintaining member of an injection molded product, if there is a gap between the inner surface of the protector or shape maintaining member and the electric wire, the electric wire collides with the inner surface of the protector or shape maintaining member due to vibration or the like. , Collision noise, etc. occur. In addition, there is a configuration to prevent impact noise by inserting a cushioning material such as sponge inside the protector and shape maintenance member of the injection molded product, but with such a configuration, the number of parts and work man-hours increase, There is a risk of increasing manufacturing costs and product prices.

本発明の実施形態にかかるワイヤーハーネスの製造方法により製造されるワイヤーハーネスによれば、電線11の所定の部分は形状維持部材12に包まれており、形状維持部材12に弾性的に接触している。このため、電線11と形状維持部材12との間で衝突音などが発生しない。また、形状維持部材12は電線11の所定の部分を衝撃や振動から保護するプロテクタや緩衝材としても機能する。このように、部品点数の増加や作業工数の増加を招かないから、部品コストや製造コストの削減を図ることができる。   According to the wire harness manufactured by the method of manufacturing the wire harness according to the embodiment of the present invention, the predetermined portion of the electric wire 11 is wrapped in the shape maintaining member 12 and elastically contacts the shape maintaining member 12. Yes. For this reason, a collision sound etc. do not generate | occur | produce between the electric wire 11 and the shape maintenance member 12. FIG. In addition, the shape maintaining member 12 also functions as a protector or cushioning material that protects a predetermined portion of the electric wire 11 from impact or vibration. As described above, since the number of parts and the number of work man-hours are not increased, it is possible to reduce the parts cost and the manufacturing cost.

また、本実施形態では、被成形体13が、熱可塑性の材料からなる不織布により成形される。したがって、形状維持部材12は、図11に示すように、空気を多く含む層となる。このような空気を多く含む層は、空気によって断熱性が向上するから、冷めにくい。そのため、本実施形態によれば、(形状維持部材がひとかたまり(バルク)であるような場合と比較して、)被成形体13を加熱および加圧してから、形状維持部材12を所定の軸線形状に成形するまでの間、形状維持部材12が冷めにくく、形状維持部材12を所定の軸線形状にする作業(第二の工程)が容易となる。つまり、形状維持部材12が「塑性変形が可能な温度にあるうち」に行わなければならない第二の工程において時間的な余裕が生まれる。   Moreover, in this embodiment, the to-be-molded body 13 is shape | molded by the nonwoven fabric which consists of a thermoplastic material. Therefore, the shape maintaining member 12 is a layer containing a large amount of air, as shown in FIG. Such a layer containing a large amount of air is hard to cool because the heat insulation is improved by the air. Therefore, according to the present embodiment, the shape maintaining member 12 is formed into a predetermined axial shape after heating and pressurizing the molded body 13 (compared to a case where the shape maintaining member is a mass (bulk)). The shape maintaining member 12 is not easily cooled until it is molded into the shape, and the work (second step) for making the shape maintaining member 12 into a predetermined axial shape becomes easy. In other words, a time margin is created in the second process that must be performed while the shape maintaining member 12 is “at a temperature at which plastic deformation is possible”.

以上、本発明の各種実施形態について詳細に説明したが、本発明は、前記各実施形態に何ら限定されるものではなく、本発明の趣旨を逸脱しない範囲において種々の改変が可能である。   As mentioned above, although various embodiment of this invention was described in detail, this invention is not limited to each said embodiment at all, and various modification | change is possible in the range which does not deviate from the meaning of this invention.

前記本発明の実施形態にかかるワイヤーハーネスの製造方法においては、形状維持部材の断面形状を略四辺形に形成する構成を示したが、形状維持部材の断面形状および寸法は、特に限定されるものではない。   In the method for manufacturing the wire harness according to the embodiment of the present invention, the configuration in which the cross-sectional shape of the shape maintaining member is formed in a substantially quadrangular shape is shown, but the cross-sectional shape and dimensions of the shape maintaining member are particularly limited. is not.

たとえば形状維持部材の本体部の断面形状または形状維持部材の全体の断面形状は、略四辺形などであってもよい。また、上下、左右に非対称な形状であってもよい。断面形状が略四辺形の場合には、下側保持具には、上側に断面略四辺形の溝状の凹部が形成される構成が適用される。そして上型には、加圧面に断面四辺形の溝状の凹部が形成される構成が適用される。このように、下側保持具の底部の上側の面の断面形状と、上型の加圧面の断面形状を種々の形状に形成することにより、ワイヤーハーネスの所定の部分の形状維持部材の断面形状を、種々の形状に成形することができる。   For example, the cross-sectional shape of the main body of the shape maintaining member or the overall cross-sectional shape of the shape maintaining member may be a substantially quadrangular shape. Further, the shape may be asymmetrical in the vertical and horizontal directions. When the cross-sectional shape is a substantially quadrangular shape, a configuration in which a groove-shaped recess having a substantially quadrangular cross-sectional shape is formed on the upper side is applied to the lower holding tool. And the structure by which the groove-shaped recessed part of a cross-sectional square shape is formed in a pressurization surface is applied to an upper mold | type. Thus, by forming the cross-sectional shape of the upper surface of the bottom of the lower holding tool and the cross-sectional shape of the pressure surface of the upper mold into various shapes, the cross-sectional shape of the shape maintaining member of the predetermined part of the wire harness Can be formed into various shapes.

また、形状維持部材の軸線形状は、ワイヤーハーネスが配索される空間の形状や配索作業の便宜などに応じて適宜設定されるものであり、限定されるものではない。   The axis shape of the shape maintaining member is appropriately set according to the shape of the space in which the wire harness is routed or the convenience of the routing operation, and is not limited.

さらに、前記実施形態においては、単一の被成形体により電線の所定の部分を包む構成を示したが、複数の被成形体により電線の所定の部分を挟むようにして包む構成であってもよい。   Furthermore, in the said embodiment, although the structure which wraps the predetermined part of an electric wire with a single to-be-molded body was shown, the structure which wraps so that the predetermined part of an electric wire may be pinched | interposed with a to-be-molded body may be sufficient.

Claims (1)

電線の所定の部分が熱可塑性の材料からなる不織布に覆われたワイヤーハーネスの製造方法であって、
電線の周囲に熱可塑性の材料からなる不織布で覆うとともに、前記熱可塑性の材料からなる不織布を熱可塑性による塑性変形が可能な温度に加熱するとともに加圧して所定の断面形状および寸法に成形する第一の工程と、
前記第一の工程の後、前記熱可塑性の材料からなる不織布が熱可塑性による塑性変形が可能な温度にあるうちに前記熱可塑性材料を所定の軸線形状に成形し、所定の軸線形状に成形した状態で冷却する第二の工程と、
を含み
前記不織布は、基本繊維とバインダ繊維とを有し、
前記基本繊維は、所定の融点を有する熱可塑性の樹脂材料からなり、
前記バインダ繊維は、芯繊維と前記芯繊維の外周に成形されるバインダ材の層とを有し、前記芯繊維は所定の融点を有する熱可塑性の樹脂材料からなり、前記バインダ材の層は前記基本繊維および前記芯繊維の融点よりも低い融点の熱可塑性の樹脂材料からなることを特徴とするワイヤーハーネスの製造方法。
A method of manufacturing a wire harness in which a predetermined part of an electric wire is covered with a nonwoven fabric made of a thermoplastic material,
The wire is covered with a non-woven fabric made of a thermoplastic material, and the non-woven fabric made of the thermoplastic material is heated to a temperature at which plastic deformation by the thermoplastic is possible and pressurized to form a predetermined cross-sectional shape and dimensions. One process,
After the first step, the thermoplastic material is molded into a predetermined axial shape while the nonwoven fabric made of the thermoplastic material is at a temperature at which plastic deformation due to thermoplasticity is possible, and is molded into a predetermined axial shape. A second step of cooling in a state;
It includes,
The non-woven fabric has basic fibers and binder fibers,
The basic fiber is made of a thermoplastic resin material having a predetermined melting point,
The binder fiber has a core fiber and a binder material layer formed on an outer periphery of the core fiber, the core fiber is made of a thermoplastic resin material having a predetermined melting point, and the binder material layer is A method of manufacturing a wire harness, comprising a thermoplastic resin material having a melting point lower than that of the basic fiber and the core fiber .
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